Page 1 OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER-UND WARTUNGS-HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ125 ( N ) /LC 5MV-28199-30...
Page 2 EC010010 YZ125(N)/LC OWNER’S SERVICE MANUAL ©2000 by Yamaha Motor Co., Ltd. 1st Edition, June 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...
Page 3 MANUALE DI SERVIZIO DEL WARTUNGSHANDBUCH DU PROPRIETAIRE PROPRIETARIO ©2000 der Yamaha Motor Co., Ltd. ©2000 Yamaha Motor Co.,Ltd. © 2000 by Yamaha Motor Co., Ltd. 1. Ausgabe, Juni 2000 1ère Edition, Juin 2000 1a Edizione, Giugno 2000 Alle Rechte vorbehalten. Tous droits réservés.
Page 4 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
Page 5 Wir möchten Ihnen zum Kauf einer Complimenti per avere acquistato una Yamaha séries YZ. Ce modèle est Yamaha YZ Serie, herzlich gratulie- Yamaha serie YZ. Questo modello è il l’aboutissement de la vaste expérience culmine della vasta esperienza della ren. Dieses Modell entspricht fort-...
Page 6 EC040001 IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be op- erated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding.
Page 7 IC040001 NOTICE IMPORTANTE WICHTIGE HINWEISE NOTA IMPORTANTE CETTE MACHINE EST STRICTE- DIESE MASCHINE IST NUR FÜR QUESTO VEICOLO È PROGETTA- MENT DESTINEE A LA COMPETI- RENNEN AUF GESCHLOSSENEN TO PER ESSERE USATO RIGORO- TION, UNIQUEMENT SUR CIRCUIT SAMENTE IN GARA, SOLTANTO KURSEN KONSTRUIERT.
Page 8 5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refuel- ing. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking. 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes,...
Page 9 5. L’ESSENCE EST HAUTE- 5. BENZIN IST BRENNBAR. 5. LA BENZINA È ALTAMEN- MENT INFLAMMABLE. Immer den Motor abstellen, TE INFIAMMABILE. Toujours arrêter le moteur en bevor aufgetankt wird. Dar- Spegnere sempre il motore faisant le plein. Faire attention auf achten, daß kein Benzin durante il rifornimento di car- à...
Page 10 Some data in this manual may become out- dated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer. EC070001 F.I.M. MACHINE WEIGHTS:...
Page 11 SECONDO LA F.I.M.: Maschine auftauchen sollten, wen- Poids des machines sans carbu- Pesi dei veicoli senza carburante den Sie sich bitte an Ihren Yamaha rant I pesi minimi per i veicoli per moto- Fachhändler. Les poids minimum admis pour les...
Page 12 EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT IN FORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN- VOLVED! Failure to follow WARNING instructions could re- sult in severe injury or death to the machine op- erator, a bystander, or a person inspecting or re- pairing the machine.
Page 13 IC080000 COMMENT VERWENDUNG COME USARE IL UTILISER CE DIESER ANLEITUNG PRESENTE MANUEL MANUALE IC 081000 INFORMATIONS WICHTIGE INFORMATION INFORMAZIONI PARTICULIEREMENT PARTICOLARMENTE Sicherheitssymbol bedeutet IMPORTANTES IMPORTANTI „AUFPASSEN“! VORSICHT GEBOTEN Le symbole d’alerte de sécurité signifie Il Simbolo di Allerta in materia di Sicu- IHRER EIGENEN SICHERHEIT.
Page 14 EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., 9Bearings...
Page 15 IC083000 FORMAT DU MANUEL FORMAT DER ANLEITUNG FORMATO DEL Dans ce manuel, toutes les procédures Allen dieser Anleitung enthaltenen MANUALE sont décrites pas à pas. Les informa- Vorgänge sind sequentiell in der Tutte le procedure contenute nel pre- tions ont été condensées pour fournir au durchzuführenden Reihenfolge aufge- sente manuale sono organizzate in for- mécanicien un guide pratique et facile à...
Page 16 EC085002 ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC INFO Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. General information INSP Specifications Regular inspection and adjustments Engine Chassis Electrical Tuning CHAS ELEC Illustrated symbols 8 to r are used to identify the specifications appearing in the text.
Page 17 IC085002 SYMBOLES GRAPHIQUES ABGEBILDETEN SYMBOLE SIMBOLI ILLUSTRATI (Voir l’illustration) (Siehe Abbildung) (Fare riferimento all’illustra- Les symboles graphiques 1 à 7 ser- Die abgebildeten Symbole 1 bis 7 zione) vent à repérer les différents chapitres et sind zur einfachen Auffindung der Sei- I simboli illustrati da 1 a 7 sono pro- à...
Page 18 EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...
Page 19 INDEX INDEX IC090010 INDICE ANALITICO ALLGEMEIN RENSEIGNEMENTS INFORMAZIONI ANGABEN GENERAUX GENERALI INFO TECHINSCHE CARACTERISTIQUES SPECIFICHE DATEN SPEC REGELMÄSSIGE VERIFICATION ET ISPEZIONE E PRÜFUNG REGLAGES REGOLAZIONI INSP COURANTS REGOLARI EINSTELLUNGEN MOTOR MOTEUR MOTORE FAHRGESTELL PARTIE CYCLE TELAIO CHAS ELEKTRISCHE PARTIE PARTE ELETTRICA EINRICHTUNGEN ELECTRIQUE ELEC...
Page 20 EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION ..........1-1 MACHINE IDENTIFICATION ......1-2 IMPORTANT INFORMATION .....1-3 CHECKING OF CONNECTION ....1-6 SPECIAL TOOLS........1-7 CONTROL FUNCTIONS......1-9 FUEL AND ENGINE MIXING OIL.....1-12 STARTING AND BREAK-IN .....1-13 TORQUE-CHECK POINTS.......1-16 CLEANING AND STORAGE ....1-17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ....2-1 MAINTENANCE SPECIFICATIONS ...2-3 GENERAL TORQUE SPECIFICATIONS..2-12...
Page 21 IC0A0000 TABLES DES INHALTSVERZEICHNIS INDICE MATIERES CAPITOLO 1 CHAPITRE 1 KAPITEL 1 INFORMAZIONI RENSEIGNEMENTS ALLGEMEIN GENERALI GENERAUX ANGABEN DESCRIPTION ...........1-1 BESCHREIBUNG ........1-1 DESCRIZIONE ...........1-1 IDENTIFICATION DE LA MACHINE ...1-2 MASCHINEN-IDENTIFIKATION....1-2 IDENTIFICAZIONE DEL VEICOLO ..1-2 INFORMATIONS IMPORTANTES ..1-3 WICHTIGE INFORMATIONEN ....1-3 INFORMAZIONI IMPORTANTI.....1-3 VÉRIFICATION DES CONNEXIONS ..1-6 ANSCHLÜSSE PRÜFEN ......1-6...
Page 22 CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS .............4-1 EXHAUST PIPE AND SILENCER ....4-3 RADIATOR..........4-4 CARBURETOR AND REED VALVE...4-7 CYLINDER HEAD , CYLINDER AND PISTON .............4-17 CLUTCH AND PRIMARY DRIVEN GEAR ............4-30 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR......4-38 YPVS GOVERNOR ........4-46 WATER PUMP ..........4-49 CDI MAGNETO .........4-53...
Page 23 CHAPITRE 4 CAPITOLO 4 KAPITEL 4 MOTEUR MOTOR MOTORE SELLE, RESERVOIR A ESSENCE SITZ, KRAFTSTOFFTANK UND SELLA, SERBATOIO DEL ET COUVERCLES LATERAUX....4-1 SEITENDECKEL.........4-1 CARBURANTE E COPERTURE LATERALI ..........4-1 TUYAU D’ECHAPPEMENT ET AUSPUFFROHR UND SILENCIEUX ..........4-3 TUBO DI SCARICO E SCHALLDÄMPFER ........4-3 SILENZIATORE.........4-3 RADIATEUR ..........4-4 KÜHLER............4-4...
Page 24 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ........6-1 IGNITION SYSTEM........6-2 CHAPTER 7 TUNING ENGINE............7-1 CHASSIS...........7-13...
Page 25 CHAPITRE 6 CAPITOLO 6 KAPITEL 6 PARTIE ELEKTRISCHE PARTE ELETTRICA ELECTRIQUE EINRICHTUNGEN COMPOSANTS ELECTRIQUES COMPONENTI ELETTRICI E SCHEMA ELEKTRISCHE BAUTEILE UND ET SCHEMA DE CABLAGE ....6-1 SCHALTPLAN ..........6-1 ELETTRICO ..........6-1 SYSTEME D’ALLUMAGE .......6-2 ZÜNDANLAGE ...........6-2 SISTEMA DI ACCENSIONE ....6-2 CHAPITRE 7 KAPITEL 7 CAPITOLO 7 MISE AU POINT...
Page 26 DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 NOTE: DESCRIPTION 1 Clutch lever 9The machine you have purchased may differ 2 ”ENGINE STOP” button slightly from those shown in the following. 3 Front brake lever 9Designs and specifications are subject to 4 Throttle grip change without notice.
Page 27 DESCRIPTION BESCHREIBUNG DESCRIZIONE INFO IC100000 RENSEIGNEMENTS ALLGEMEIN INFORMAZIONI GENERAUX ANGABEN GENERALI IC110000 DESCRIPTION BESCHREIBUNG DESCRIZIONE 1 Levier d’embrayage 1 Kupplungshebel 1 Leva di comando della frizione 2 Bouton de coupe-circuit de sécurité 2 Motorstoppknopf „ENGINE STOP“ 2 Pulsante “ARRESTO MOTORE” 3 Handbremshebel “ENGINE STOP”...
Page 28 There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive iden- tification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
Page 29 Seriennummer ange- cessionario Yamaha per un’identi- Yamaha qui pourra identifier clai- geben werden, damit Ihr Yamaha ficazione certa del modello posse- rement le modèle correspondant à Fachhändler das Modell richtig duto.
Page 30 IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign ma- terial before removal and disassembly. When washing the machine with high pres- sured water, cover the parts as follows. 9Silencer end 9Air filter intake slit 9Crankcase cover hole at the bottom...
Page 31 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO IC130000 INFORMATIONS WICHTIGE INFORMAZIONI IMPORTANTES INFORMATIONEN IMPORTANTI IC131010 PREPARATION POUR LA DEPO- VORBEREITUNG FÜR DEN PREPARAZIONE PER LA RIMO- SE ET DEMONTAGE AUSBAU UND DER DEMONTAGE ZIONE E LO SMONTAGGIO 1. Eliminer soigneusement crasse, 1.
Page 32 IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for as- sembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled.
Page 33 Yamaha per tutti i ricambi. Bauteile zu verwenden. Für Ein- les remplacements. Utiliser les Usare olio e/o grasso raccomandati bau und Einstellungen nur das huiles/graisses recommandées par dalla Yamaha per il montaggio e la Yamaha empfohlene Öl Yamaha lors des remontages et regolazione.
Page 34 IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully be- fore reassembly. Always replace piston pin clips after one use. Replace distorted cir- clips. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite to the thrust 3 it receives.
Page 35 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO IC136000 CIRCLIPS SICHERUNGSRINGE ANELLI ELASTICI DI ARRESTO 1. Avant remontage, tous les circlips 1. Alle Sicherungsringe vor dem Wie- 1. Si dovrebbero ispezionare attenta- doivent être soigneusement véri- dereinbau gründlich prüfen. Die mente tutti gli anelli elastici di fiés.
Page 36 CHECKING OF CONNECTION INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: 9Connector 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 VÉRIFICATION DES CONNEXIONS ANSCHLÜSSE PRÜFEN CONTROLLO DEI COLLEGAMENTI INFO IC1C0001 VÉRIFICATION DES ANSCHLÜSSE PRÜFEN CONTROLLO DEI Bei Flecken, Rost, Feuchtigkeit u.ä. CONNEXIONS COLLEGAMENTI auf einem Steckverbinder: Traitement des taches, de la rouille, de Come trattare macchie, ruggine, umi- 1. Lösen: l’humidité, etc.
Page 38 SPECIAL TOOLS INFO EC140001 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and part number used for the special tool differ by country, so two types are provid- ed.
Page 39 Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the igni- tion system components. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc.
Page 40 OUTILS SPECIAUX INFO OUTILS SPECIAUX Les outils spéciaux appropriés sont indispensables pour pouvoir effectuer un assemblage et une mise au point complets et précis. L’utilisation des outils spéciaux corrects permettra d’éviter les endommagements dus à l’emploi d’outils impropres et aux techniques improvisées entraînées par ceux-ci. La forme et le numéro de pièce des outils spéciaux diffèrent selon les pays.
Page 41 Outil d’insertion de joint de fourche YM-01442 90890-01442 Cet outil est utilisé pour monter les bagues d’étanchéité de fourche. YU-3112-C, Testeur de poche Yamaha YU-3112-C 90890-03112 90890-03112 Utiliser cet outil pour examiner la résistance de bobine, la tension de sortie et l’intensité.
Page 42 SPEZIALWERKZEUGE INFO SPEZIALWERKZEUGE Die folgenden Spezialwerkzeuge sind für korrekte und vollständige Einstell- und Montagearbeiten unerläßlich. Durch die Verwendung dieser Werkzeuge können Beschädigungen vermieden werden, die beim Gebrauch ungeeigneter Hilfsmittel oder improvisierter Techniken entstehen können. Bei der Bestellung von Spezialwerkzeug sollten die im folgenden aufgeführten Bezeichnungen und Teilenummern angegeben werden.
Page 43 YM-34487 Dynamischen Zündfunkenprüfer YM-34487 90890-06754 90890-06754 Zündungs-Prüfgerät Dieses Prüfgerät wird für die Kontrolle der Bauteile der Zündanlage benötigt. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA bond Nr. 1215 Dieses Dichmittel wird für die Paßflächen der Kurbel- gehäusehälften usw. verwendet.
Page 44 UTENSILI SPECIALI INFO IC140001 UTENSILI SPECIALI Per una messa a punto e un montaggio completi e accurati sono necessari gli utensili speciali adeguati. L’uso dell'utensile speciale corretto contribuirà a evitare danni provocati dall’uso di utensili impropri o di tecniche improvvisate. La forma e il numero categorico usati per l’utensile speciale sono diversi a seconda del paese, quindi vengono forniti due tipi.
Page 45 90890-06754 Controllore dell'accensione Questo strumento è necessario per controllare i compo- nenti del sistema di accensione. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No. 1215 Questo sigillante (agglomerante) viene usato per la superficie di accoppiamento del carter, ecc..
Page 46 CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS EC151000 “ENGINE STOP” BUTTON The “ENGINE STOP” button 1 is located on the left handlebar. Continue pushing the “ENGINE STOP” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left handle- bar;...
Page 47 FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI INFO IC150000 FONCTIONS DES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI COMMANDES IC151000 BOUTON D’ARRET DE MOTEUR MOTORSTOPPKNOPF „ENGINE PULSANTE “ARRESTO “ENGINE STOP” STOP“ MOTORE” Ce bouton d’arrêt de moteur “ENGINE Il pulsante “ARRESTO MOTORE” 1 Dieser Motorstoppknopf „ENGINE...
Page 48 CONTROL FUNCTIONS INFO EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to acti- vate the front brake. EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine.
Page 49 FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI INFO IC156000 LEVIER DE FREIN AVANT HANDBREMSHEBEL LEVA DI COMANDO DEL FRENO Le levier de frein avant 1 se trouve sur Der Handbremshebel 1 (Vorderrad- ANTERIORE le guidon droit. Le tirer vers le guidon bremse) befindet sich am rechten La leva di comando del freno anteriore 1 è...
Page 50 CONTROL FUNCTIONS INFO EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. In this installation, make sure the arrow faces the fuel tank and also downward. EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it.
Page 51 FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI INFO IC15F000 GIUNTO DELLA VALVOLA JOINT DE ROBINET VENTILVERBINDUNG Questo giunto della valvola 1 impedi- Ce joint de robinet 1 evite que l’essen- Diese Ventilverbindung 1 verhindert sce che il carburante fuoriesca ed è ce ne s’échappe et est monté...
Page 52 FUEL AND ENGINE MIXING OIL INFO EC160050 FUEL AND ENGINE MIXING OIL Mix oil with the gas at the ratio specified below. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old.
Page 53 ESSENCE ET HUILE DE MELANGE DU MOTEUR KRAFTSTOFF UND MOTORGEMISCHÖL CARBURANTE E OLIO PER MISCELA PER MOTORI INFO IC160050 KRAFTSTOFF UND ESSENCE ET HUILE DE CARBURANTE E OLIO MELANGE DU MOTEUR MOTORGEMISCHÖL PER MISCELA PER MOTORI Mélanger le carburant à l’huile dans les Öl im nachfolgend angegebenen Ver- Miscelare l’olio con la benzina nel rap- proportions indiquées ci-dessous.
Page 54 STARTING AND BREAK-IN INFO EC190000 STARTING AND BREAK-IN Before starting the machine, perform the checks in the pre-operation check list. Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time.
Page 55 MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN AVVIAMENTO E RODAGGIO INFO IC190000 STARTEN UND EINFAHREN MISE EN MARCHE ET AVVIAMENTO E RODAGE RODAGGIO Avant la mise en marche, effectuez Vor dem Anfahren der Maschine, Prima di avviare il veicolo, eseguire i les vérifications indiquées dans la unbedingt die unter „Prüfungen vor controlli della lista di controllo prima...
Page 56 STARTING AND BREAK-IN INFO EC194001 BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows. Mixing oil: Mixing ratio: Yamalube “2-R” 15:1 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “ENGINE STOP”...
Page 57 MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN AVVIAMENTO E RODAGGIO INFO IC194001 PROCEDURE DE RODAGE EINFAHRVORGÄNGE PROCEDURE DI RODAGGIO 1. Vor dem Starten des Motors, den 1. Avant de lancer le moteur, rem- 1. Prima di avviare il motore, riempi- Kraftstofftank für das Einfahren mit plissez le réservoir d’un mélange re il serbatorio del carburante con...
Page 58 STARTING AND BREAK-IN INFO 9After the break-in or before each race, you must check the entire machine for loose fit- tings and fasteners as per “TORQUE- CHECK POINTS”. Tighten all such fasteners as required. 9When any of the following parts have been replaced, they must be broken in.
Page 59 MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN AVVIAMENTO E RODAGGIO INFO 9 Après le rodage ou avant chaque 9 Nach dem Einfahren und vor 9 Dopo il rodaggio o prima di ciascu- course, il faut vérifier toutes les jedem Rennen müssen Sie gemäß na gara, si deve controllare tutto il fixations et serrages comme indiqué...
Page 60 TORQUE-CHECK POINTS INFO EC1A0012 TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and tank Fuel tank to frame Engine mounting Frame to engine Steering Steering shaft to Steering shaft to frame handlebar Steering shaft to handle crown Handle crown to handlebar Suspension Front Steering shaft to...
Page 61 POINTS DE VERIFICATION DE COUPLE DE SERRAGE INFO POINTS DE VERIFICATION DE COUPLE DE SERRAGE Construction du cadre Du cadre au cadre arrière Combinasion de siège Du réservoir à essence au cadre et de réservoir Montage du moteur Du cadre au moteur Direction De l’arbre de De l’arbre de direction au cadre...
Page 62 ANZUGSMOMENTE-PRÜFPUNKTE INFO ANZUGSMOMENTE-PRÜFPUNKTE Rahmenkonstruktion Rahmen und Hintere Rahmen Kombinierter Sitz und Tank Kraftstofftank am Rahmen Motoraufhängung Rahmen am Motor Lenkung Lenkerschaft Lenkerschaft am Rahmen an Lenkstange Lenkerschaft an Lenkerkrone Lenkerkrone an Lenkstange Radaufhängung Vorne Lenkerschaft an Vorderradgabel an Lenkerkrone Vorderradgabel Vorderradgabel an Unterkonsole Hinten Für Gestängetyp...
Page 63 PUNTI DI CONTROLLO DELLA COPPIA INFO IC1A0012 PUNTI DI CONTROLLO DELLA COPPIA Costruzione del telaio Telaio-telaio posteriore Sella e serbatoio uniti Serbatoio del carburante-telaio Supporto del motore Telaio-motore Sterzo Albero dello Albero dello sterzo-telaio sterzo-manubrio Albero dello sterzo-corona del manubrio Corona del manubrio-manubrio Sospensione Anteriore...
Page 64 CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall perfor- mance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.
Page 65 NETTOYAGE ET RANGEMENT REINIGEN UND LAGERUNG PULITURA E IMMAGAZZINAMENTO INFO IC1B0000 REINIGEN UND NETTOYAGE ET PULITURA E IMMAGAZZI- RANGEMENT LAGERUNG NAMENTO NETTOYAGE REINIGEN IC1B1000 Häufiges Reinigen Ihrer Maschine Un nettoyage fréquent de la machine PULITURA stellt gefälliges Aussehen und ausge- réhausserra son aspect, maintiendra ses Una pulitura frequente del veicolo ne zeichnetes Leistungsvermögen sicher...
Page 66 CLEANING AND STORAGE INFO EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the ma- chine thoroughly, prepare it for storage as fol- lows: 1.
Page 67 NETTOYAGE ET RANGEMENT REINIGEN UND LAGERUNG PULITURA E IMMAGAZZINAMENTO INFO IC182001 RANGEMENT LAGERUNG IMMAGAZZINAMENTO Si vous remisez votre machine pour 60 Falls Ihre Maschine für länger als Se il veicolo deve essere immagazzina- jours ou plus, vous devez prendre des etwa 60 Tage gelagert werden soll, to per 60 giorni o più, si devono pren- mesures de conservation pour éviter sa...
Page 68 SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: YZ125LC (EUROPE) YZ125N1 (USA) YZ125(N) (CDN, AUS, NZ, ZA) Model code number: 5MV1 (USA, CDN, ZA) 5MV2 (EUROPE) 5MV4 (AUS, NZ) Dimensions: USA, CDN, ZA EUROPE AUS, NZ Overall length 2,139 mm 2,136 mm 2,139 mm...
Page 69 SPEC GENERAL SPECIFICATIONS Carburetor: χ 38SS/MIKUNI Type/Manufacturer Spark plug: Type/Manufacturer BR9EG/NGK 0.5~0.6 mm (0.020~0.024 in) Clutch type: Wet, multiple-disc Transmission: Primary reduction system Gear Primary reduction ratio 64/19 (3.368) Secondary reduction system Chain drive Secondary reduction ratio 48/13 (3.692) Transmission type Constant mesh, 6-speed Operation Left foot operation...
Page 70 SPEC MAINTENANCE SPECIFICATIONS EC212000 MAINTENANCE SPECIFICATIONS EC212100 ENGINE Item Standard Limit Cylinder head: … Combustion chamber capacity 10.2 cm (0.359 Imp oz, 0.345 US oz) … Warp limit 0.03 mm (0.0012 in) Cylinder: Bore size 54.000~54.014 mm 54.1 mm (2.130 in) (2.1260~2.1265 in) …...
Page 71 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Transmission: … Main axle deflection limit 0.01 mm (0.0004 in) … Drive axle deflection limit 0.01 mm (0.0004 in) Shifter: … Shifting type Cam drum and guide bar … Guide bar bending limit 0.05 mm (0.0020 in) …...
Page 72 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb M14 ´ 1.25 Spark plug M 8 ´ 1.25 Cylinder head (nut) M 8 ´ 1.25 (stud) M 8 ´ 1.25 Cylinder (nut) M10 ´ 1.25 (stud) Power valve: M 5 ´...
Page 73 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb M 6 ´ 1.0 Exhaust pipe M 6 ´ 1.0 Exhaust pipe stay (front) M 6 ´ 1.0 Exhaust pipe stay (rear) M 6 ´ 1.0 Silencer (front) M 6 ´...
Page 74 SPEC MAINTENANCE SPECIFICATIONS EC212201 CHASSIS Item Standard Limit Steering system: … Steering bearing type Taper roller bearing Front suspension: USA, CDN, ZA EUROPE AUS, NZ … ¬ Front fork travel 300 mm (11.8 in) ¬ Fork spring free length 460 mm (18.1 in) 455 mm (17.9 in) …...
Page 75 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Wheel: … Front wheel type Spoke wheel … Rear wheel type Spoke wheel … 21 ´ 1.60/Aluminum Front rim size/Material … 19 ´ 1.85/Aluminum Rear rim size/Material Rim runout limit: … Radial 2.0 mm (0.08 in) Lateral …...
Page 76 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb M 8 ´ 1.25 Handle crown and outer tube M 8 ´ 1.25 Under bracket and outer tube M24 ´ 1.0 Handle crown and steering shaft 14.5 M 8 ´...
Page 77 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb M 6 ´ 1.0 Rear brake master cylinder and frame M 6 ´ 1.0 Rear brake reservoir tank and frame M10 ´ 1.25 Rear brake hose union bolt (caliper) M10 ´...
Page 78 32°/3000 r/min … 0.52 mm (0.020 in) … Advancer type Electrical CDI: … Magneto-model/Manufacturer F4SS00/YAMAHA … 720~1,080 ½ at 20°C (68°F) Source coil 1 resistance (color) (Green/White-Black/Red) … 44~66 ½ at 20°C (68°F) Source coil 2 resistance (color) (Black-Green/Blue) …...
Page 79 GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard faste- ners with standard I.S.O. pitch threads. Torque specifications for special components or assem- blies are included in the applicable sections of this book. To avoid warpage, tighten multi-faste- ner assemblies in a crisscross fashion, in pro- gressive stages, until full torque is reached.
Page 80 SPEC CARACTERISTIQUES GENERALES CARACTERISTIQUES CARACTERISTIQUES GENERALES Nom de modèle: YZ125LC (EUROPE) YZ125N1 (USA) YZ125(N) (CDN, AUS, NZ, ZA) Numéro de code de modèle: 5MV1 (USA, CDN, ZA) 5MV2 (EUROPE) 5MV4 (AUS, NZ) Dimensions: USA, CDN, ZA EUROPE AUS, NZ Longueur hors-tout 2.139 mm 2.136 mm 2.139 mm...
Page 81 SPEC CARACTERISTIQUES GENERALES Carburateur: TMX χ 38SS/MIKUNI Type/fabricant Bougie: Type/fabricant BR9EG/NGK Ecartement des électrodes 0,5~0,6 mm (0,020~0,024 in) Type d’embrayage: Humide, multi-disques Transmission: Système de réduction primaire Engrenage Taux de réduction primaire 64/19 (3,368) Système de réduction secondaire Entraînement par chaîne Taux de réduction secondaire 48/13 (3,692) Type de boîte de vitesse...
Page 82 SPEC CARACTERISTIQUES D’ENTRETIEN CARACTERISTIQUES D’ENTRETIEN MOTEUR Article Standard Limite Culasse: … Capacité de la chambre de combustion 10,2 cm (0,359 Imp oz, 0,345 US oz) … Limite de déformation 0,03 mm (0,0012 in) Cylindre: Alésage 54,000~54,014 mm 54,1 mm (2,130 in) (2,1260~2,1265 in) …...
Page 83 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Boîte de vitesses: … Limite de déformation d’arbre primaire 0,01 mm (0,0004 in) Limite de déformation d’arbre secondaire … 0,01 mm (0,0004 in) Selécteur: Tambour de came et barre de guidage … Type de sélecteur …...
Page 84 SPEC CARACTERISTIQUES D’ENTRETIEN Taille de Couple de serrage Pièce à serrer Q’té filetage m•kg ft•lb M14 ´ 1,25 Bougie M 8 ´ 1,25 Culasse (écrou) M 8 ´ 1,25 (goujon) M 8 ´ 1,25 Cylindre (écrou) M10 ´ 1,25 (goujon) Clapet de puissance: M 5 ´...
Page 85 SPEC CARACTERISTIQUES D’ENTRETIEN Taille de Couple de serrage Pièce à serrer Q’té filetage m•kg ft•lb M 6 ´ 1,0 Tuyau d’échappement M 6 ´ 1,0 Support de tuyau d’échappement (avant) M 6 ´ 1,0 Support de tuyau d’échappement (arrière) M 6 ´ 1,0 Silencieux (avant) M 6 ´...
Page 86 SPEC CARACTERISTIQUES D’ENTRETIEN PARTIE-CYCLE Article Standard Limite Direction: … Type de roulement de direction Roulement à rouleaux conique Suspention avant: USA, CDN, ZA EUROPE AUS, NZ ¬ … Débattement de fourche avant 300 mm (11,8 in) ¬ Longueur libre de ressort de fourche 460 mm (18,1 in) 455 mm (17,9 in) …...
Page 87 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Roue: … Type de roue avant Roue à rayons … Type de roue arrière Roue à rayons 21 ´ 1,60/Aluminum … Taille/matériau de jante avant 19 ´ 1,85/Aluminum … Taille/matériau de jante arrière Limite de voile de jante: …...
Page 88 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Q’té filetage m•kg ft•lb M 8 ´ 1,25 Couronne de guidon et tube externe M 8 ´ 1,25 Etrier inférieur et tube externe M24 ´ 1,0 Couronne de guidon et colonne de direction 14,5 M 8 ´...
Page 89 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Q’té filetage m•kg ft•lb M 6 ´ 1,0 Maître-cylindre de frein arrière et cadre M 6 ´ 1,0 Réservoir de frein arriére et cadre M10 ´ 1,25 Boulon d’union de tuyau de frein arrière (ètrier) M10 ´...
Page 90 … 0,52 mm (0,020 in) … Type de dispositif d’avance Electrique CDI: … Magnéto-modèle/Fabricant F4SS00/YAMAHA … 720~1.080 ½ à 20°C (68°F) Résistance de bobinage de source 1 (couleur) (vert/blanc-noir/rouge) … 44~66 ½ à 20°C (68°F) Résistance de bobinage de source 2...
Page 91 SPECIFICATIONS GENERALES DE COUPLE/ SPEC DEFINITION DES UNITES SPECIFICATIONS GENERALES DE COUPLE Ce tableau spécifie les couples de serrage des at- taches standard avec filetage à pas I.S.O. standard. Les spécifications de couple pour les composants ou ensembles spéciaux sont indiquées das les sec- tions appropriées de ce manuel.
Page 92 SPEC ALLGEMEINE TECHNISCHE DATEN TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN Modellname: YZ125LC (EUROPA) YZ125N1 (USA) YZ125(N) (CDN, AUS, NZ, ZA) Modell-Code-Nummer: 5MV1 (USA, CDN, ZA) 5MV2 (EUROPA) 5MV4 (AUS, NZ) Abmessungen: USA, CDN, ZA EUROPA AUS, NZ Gesamtlänge 2.139 mm 2.136 mm 2.139 mm (84,2 in) (84,1 in)
Page 93 SPEC ALLGEMEINE TECHNISCHE DATEN Vergaser: χ 38SS/MIKUNI Modell/Hersteller Zündkerze: Modell/Hersteller BR9EG/NGK Elektrodenabstand 0,5~0,6 mm (0,020~0,024 in) Kupplungsbauart: Mehrscheiben-Naßkupplung Getriebe: Primäruntersetzungssystem Zahnrad Primäruntersetzungsverhältnis 64/19 (3,368) Sekundäruntersetzungssystem Kettenantrieb Sekundäruntersetzungsverhältnis 48/13 (3,692) Getriebebauart Syncrongetriebe, 6-Gang Bedienungssystem Linker Fuß Untersetzungsverhältnis: 1. Gang 30/13 (2,307) 2.
Page 94 SPEC WARTUNGSDATEN WARTUNGSDATEN MOTOR Bauteil Standard Grenze Zylinderkopf: … Brennkammerkapazität 10,2 cm (0,359 Imp oz, 0,345 US oz) … Verzugsgrenze 0,03 mm (0,0012 in) Zylinder: Bohrungsdurchmesser 54,000~54,014 mm 54,1 mm (2,130 in) (2,1260~2,1265 in) … Konizitäts-Verschleißgrenze 0,05 mm (0,0020 in) …...
Page 95 SPEC WARTUNGSDATEN Bauteil Standard Grenze Getriebe: … Schlaggrenze der Haptwelle 0,01 mm (0,0004 in) … Schlaggrenze der Antriebswelle 0,01 mm (0,0004 in) Schaltung: … Schaltungsart Nockenwalze und Führungsstange Durchbiegungsgrenze der … 0,05 mm (0,0020 in) Führungsstange … Kickstarter: Bauart Sekundär-Kickstarter …...
Page 96 SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M14 ´ 1,25 Zündkerze M 8 ´ 1,25 Zylinderkopf (Mutter) M 8 ´ 1,25 (Stehbolzen) M 8 ´ 1,25 Zylinder (Mutter) M10 ´ 1,25 (Stehbolzen) Leistungsventil: M 5 ´ 0,8 Deckel M 4 ´...
Page 97 SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M 6 ´ 1,0 Auspuffrohr M 6 ´ 1,0 Auspuffrohrstütze (Vorne) M 6 ´ 1,0 Auspuffrohrstütze (Hinten) M 6 ´ 1,0 Schalldämpfer (Vorne) M 6 ´ 1,0 Schalldämpfer (Hinten) M 6 ´ 1,0 Fasereinsatz (Schalldämpfer)
Page 98 SPEC WARTUNGSDATEN FAHRGESTELL Bauteil Standard Grenze Lenkungssystem: … Lenkerschaftlager Kegelrollenlager Vorderradaufhängung: USA, CDN, ZA, EUROPA AUS, NZ … ¬ Hub der Vorderradgabel 300 mm (11,8 in) ¬ Ungespannte Federlänge 460 mm (18,1 in) 455 mm (17,9 in) … Federkonstante STD K=4,10 N/mm K=ca.
Page 99 SPEC WARTUNGSDATEN Bauteil Standard Grenze Räder: … Bauart: Vorderrad Speichenräder … Hinterrad Speichenräder … 21 ´ 1,60/Aluminum Felgengröße: Vorderrad/Baustoff … 19 ´ 1,85/Aluminum Hinterrad/Baustoff Zuläßiger Felgenschlag: … Senkrecht 2,0 mm (0,08 in) Seitlich … 2,0 mm (0,08 in) Antriebskette: Bauart/Hersteller DID520DMA2 SDH/DAIDO …...
Page 100 SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M 8 ´ 1,25 Lenkerkrone und äußere Rohr M 8 ´ 1,25 Untere Gabelbrücke und äußere Rohr M24 ´ 1,0 Lenkerkrone und Lenkerschaft 14,5 M 8 ´ 1,25 Lenkerhalter (Obere) M28 ´ 1,0 Lenkerringmutter Siehe ANMERKUNG M48 ´...
Page 101 SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M 6 ´ 1,0 Hinterrad-Hauptbremszylinder und Rahmen M 6 ´ 1,0 Hinterradbremse-Ausgleichbehälter und Rahmen M10 ´ 1,25 Hinterrad-Bremsschlauch- Verbindungsschraube (Bremssattel) M10 ´ 1,25 Hinterrad-Bremsschlauch- Verbindungsschraube (Hauptbremszylinder) M20 ´ 1,5 Hinterradachse und Mutter 12,5 Nippeln (Speichen) –...
Page 102 … (Vor dem oberen Totpunkt) 0,52 mm (0,020 in) … Zündversteller Elektrisch-Ausführung CDI: … Modell/Hersteller F4SS00/YAMAHA … 720~1.080 ½ bei 20°C (68°F) Widerstand der Stromspule 1 (Farbe) (Grün/Weiß-Schwarz/Rot) … 44~66 ½ bei 20°C (68°F) Widerstand der Stromspule 2 (Farbe) (Schwarz-Grün/Blau) …...
Page 103 ALLGEMEINE ANZUGSDATEN/ SPEC DEFINITION DER EINHEITEN ALLGEMEINE ANZUGSDATEN Diese Tabelle spezifiziert Anzugsmomente für normale Befestigungselemente mit normalen I.S.O. Gewindenormen. Anzugsmomente für be- sondere Bauteile bzw. Bauteileinheiten sind in einzelnen Abschnitten dieser Wartungsanleitung aufgefügrt. Wenn Teile mit mehreren Befestigungselementen festgezogen werden, die Schrauben und Muttern kreuzweise und in mehreren Schritten bis zum vorgeschrie- benen Anzusgsmoment festziehen, so daß...
Page 104 SPEC SPECIFICHE GENERALI IC200000 SPECIFICHE IC211000 SPECIFICHE GENERALI Nome del modello: YZ125LC (EUROPA) YZ125N1 (USA) YZ125(N) (CDN, AUS, NZ, ZA) Numero di codice del modello: 5MV1 (USA, CDN, ZA) 5MV2 (EUROPA) 5MV4 (AUS, NZ) Dimensioni: USA, CDN, ZA EUROPA AUS, NZ Lunghezza totale 2.139 mm 2.136 mm...
Page 105 SPEC SPECIFICHE GENERALI Carburatore: TMX χ 38SS/MIKUNI Tipo/Costruttore Candela: Tipo/Costruttore BR9EG/NGK Distanza tra gli elettrodi 0,5~0,6 mm (0,020~0,024 in) Tipo di frizione: Bagnata, a più dischi Trasmissione: Sistema di riduzione primario Ingranaggio Rapporto di riduzione primario 64/19 (3,368) Sistema di riduzione secondario Trasmissione a catena Rapporto di riduzione secondario 48/13 (3,692)
Page 106 SPEC SPECIFICHE DI MANUTENZIONE IC212000 SPECIFICHE DI MANUTENZIONE IC212100 MOTORE Voce Valore normale Limite Testa cilindro: … Capacità della camera di combustione 10,2 cm (0,359 Imp oz, 0,345 US oz) … Limite di deformazione 0,03 mm (0,0012 in) Cilindro: Alesaggio 54,000~54,014 mm 54,1 mm (2,130 in) (2,1260~2,1265 in)
Page 107 SPEC SPECIFICHE DI MANUTENZIONE Voce Valore normale Limite Trasmissione: … Limite di inflessione dell’asse principale 0,01 mm (0,0004 in) … Limite di inflessione dell’asse motore 0,01 mm (0,0004 in) Cambio: Tamburo a camme e guida di scorrimento … Tipo di cambio …...
Page 108 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni della Parte da serrare Quantità filettatura m•kg ft•lb M14 ´ 1,25 Candela M 8 ´ 1,25 Testa cilindro (dado) M 8 ´ 1,25 (prigioniero) M 8 ´ 1,25 Cilindro (dado) M10 ´ 1,25 (prigioniero) Valvola di potenza: M 5 ´...
Page 109 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni della Parte da serrare Quantità filettatura m•kg ft•lb M 6 ´ 1,0 Tubo di scarico M 6 ´ 1,0 Puntello del tubo di scarico (anteriore) M 6 ´ 1,0 Puntello del tubo di scarico (posteriore) M 6 ´...
Page 110 SPEC SPECIFICHE DI MANUTENZIONE IC212201 TELAIO Voce Valore normale Limite Sistema dello sterzo: … Tipo di cuscinetto dello sterzo Cuscinetto a sfere conico Sospensione anteriore: USA, CDN, ZA, EUROPA AUS, NZ ¬ … Corsa della forcella anteriore 300 mm (11,8 in) ¬...
Page 111 SPEC SPECIFICHE DI MANUTENZIONE Voce Valore normale Limite Ruota: … Tipo di ruota anteriore Ruota a razze … Tipo di ruota poster Ruota a razze 21 ´ 1,60/Alluminio … Dimensioni/Materiale del cerchione anteriore Dimensioni/Materiale del cerchione posteriore 19 ´ 1,85/Alluminio …...
Page 112 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni della Quantità Parte da serrare filettatura m•kg ft•lb M 8 ´ 1,25 Corona del manubrio e tubo esterno M 8 ´ 1,25 Staffa inferiore e tubo esterno M24 ´ 1,0 Corona del manubrio e albero dello sterzo 14,5 M 8 ´...
Page 113 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni della Quantità Parte da serrare filettatura m•kg ft•lb M 6 ´ 1,0 Cilindro principale del freno posteriore e telaio M 6 ´ 1,0 Serbatoio di riserva del freno posteriore e telaio M10 ´ 1,25 Bullone di unione del tubo flessibile del freno posteriore (pinza) M10 ´...
Page 114 … 0,52 mm (0,020 in) … Tipo di anticipatore Elettrico CDI: … Modello/Costruttore del magnete F4SS00/YAMAHA … 720~1.080 ½ à 20°C (68°F) Resistenza 1 della bobina di origine (colore) (Verde/Bianco-Nero/Rosso) 44~66 ½ à 20°C (68°F) … Resistenza 2 della bobina di origine...
Page 115 SPECIFICHE GENERALI RELATIVE ALLA COPPIA/ SPEC DEFINIZIONE DELLE UNITÀ IC220001 SPECIFICHE GENERALI RELATIVE ALLA COPPIA Questa tabella specifica la coppia per i dispositivi di fissaggio standard con filettature a passo I.S.O. standard. Le specifiche relative alla coppia per componenti o gruppi speciali sono incluse nelle se- zioni pertinenti di questo manuale.
Page 116 SPEC CABLE ROUTING DIAGRAM EC240000 C Clamp the throttle cable and 1 Brake hose hose inside the YPVS 2 Fuel tank breather hose “ENGINE STOP” button lead breather hose. H Clamp the radiater breather 3 Cable guide to the frame. With the clamp 4 Clamp ends downward, tighten the hose and CDI magneto lead...
Page 117 SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI IC240000 SCHEMA DE KABELFÜHRUNGSÜBER- DIAGRAMMA DEL CHEMINEMENT DES SICHTPLAN PASSAGGIO DEI CAVI 1 Tubo flessibile del freno 1 Bremsschlauch CABLES 2 Kraftstofftank-Belüftungsschlauch 2 Sfiato del serbatoio del carburante 1 Tuyau de frein 3 Kabelführung 3 Guida per cavi...
Page 118 SPEC CABLE ROUTING DIAGRAM B If the brake hose contacts I Pass the clutch cable over 1 Brake hose holder 2 Master cylinder the spring (rear shock the radiator hose. J Clamp the wireharness on 3 Brake hose absorber), correct its twist. C Install the brake hose so that 4 Hose guide the top of the CDI unit with...
Page 119 SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Support de tuyau de frein 1 Bremsschlauchhalter 1 Supporto del tubo flessibile del freno 2 Maître-cylindre 2 Hauptbremszylinder 2 Cilindro principale 3 Tuyau de frein 3 Bremsschlauch 3 Tubo flessibile del freno 4 Guide de tuyau 4 Schlauchführung...
Page 120 SPEC CABLE ROUTING DIAGRAM A Install the brake hose so that its pipe portion 1 Brake hose 2 Master cylinder directs as show and lightly touches the 3 “ENGINE STOP” button lead projection on the master cylinder. B Pass the “ENGINE STOP” button lead in 4 “ENGINE STOP”...
Page 121 SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Tuyau de frein 1 Bremsschlauch 1 Tubo flessibile del freno 2 Maître-cylindre 2 Hauptbremszylinder 2 Cilindro principale 3 Fil de bouton d’arrêt du moteur “ENGI- 3 Leitungskabel des Motorstoppknopfes 3 Conduttore del pulsante “ARRESTO NE STOP”...
Page 122 If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. After...
Page 123 Replace bearing TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE, CONTROL CABLE Yamaha cable lube or Check routing and connection SAE 10W-30 motor oil Lubricate...
Page 124 INSP MEMO...
Page 125 En cas de doute au sujet des inter- valles d’entretien et de lubrification à adopter, consultez votre concessionnaire Yamaha. Chaque Chaque Après Chaque...
Page 126 INSP PROGRAMME D’ENTRETIEN Chaque Chaque Après Chaque Partie trois- cinquiè- nécessa- Remarques rodage course ième CIRCUIT DE REFROIDISSEMENT Contrôler le niveau du liquide de refroidissement et s’il n’y a pas de fuite Contrôler le fonctionnement du bouchon de radiateur Changer le liquide de Chaque deux ans refroidissement Contrôler les tuyaux...
Page 127 Resserrer les boulons de la roue dentée Contrôler les roulements Changer les roulements Graisser Graisse à base de lithium ACCELERATEUR, CABLES DE COMMANDE Yamaha lube pour câble ou Contrôler le chaminement et le Huile moteur SAE 10W-30 branchement Graisser...
Page 128 Wetterbedingungen, dem Terrain, der geographischen Lage und den individuellen Fahrgewohnhei- ten sind die aufgeführten Wartungs- und Schmierintervalle zu ändern. Falls Fragen hinsichtlich der War- tungs- und Schmierintervalle auftreten sollten, wenden Sie sich bitte an Ihren Yamaha Fachhändler. Nach...
Page 129 INSP WARTUNGSINTERVALLE Nach Nach Nach Nach dem jedem jedem Benennung jedem Bemerunen Einfahren dritten fünften Erforderlich Rennen Rennen Rennen KÜHLANLAGE Kühlmittelstand prüfen und auf Undichtigkeit achten Funktion des Kühlerdeckels kontrollieren Kühlmittel wechseln Alle zwie Jahre Schläuche prüfen MUTTERN UND SCHRAUBEN Siehe Abschnitt AN DER AUSSENSEITE „STARTEN UND...
Page 130 Bemerunen Einfahren dritten fünften Erforderlich Rennen Rennen Rennen RÄDER, REIFEN Reifendruck, Felgenschlag, Reifenverschleiß und Speichen auf Lockerung prüfen Ketternrad-Befestigungsschraube nachziehen Lager prüfen Lager erneuern Schmieren Lithium-Fett GASDREHGRIFF, GASSEIL Yamaha Seilzug- Seilzugführung und Anschlüsse Schmiermittel oder prüfen Motoröl SAE 10W-30 Schmieren...
Page 131 Se si hanno dubbi sugli interval- li da seguire per la manutenzione e la lubrificazione del veicolo, consultare il concessionario Yamaha. In base...
Page 132 INSP INTERVALLI DI MANUTENZIONE In base Dopo il Ogni Ogni Voce Ogni alle Osservazioni rodaggio gara cinque necessità IMPIANTO DI RAFFREDDAMENTO Controllo livello e perdite di liquido refrigerante Controllo funzionamento del tappo del radiatore Sostituzione del liquido refrigerante Ogni due anni Ispezione dei tubi flessibili DADI E VITI ESTERNI Consultare la sezione...
Page 133 Riserraggio bullone del rocchetto Ispezione dei cuscinetti Sostituzione dei cuscinetti Lubrificazione Grasso a base di litio VALVOLA A FARFALLA, CAVO DI COMANDO Lubrificante per cavi Controllo dell’instradamento e del Yamaha oppure olio per collegamento motori SAE 10W-30 Lubrificazione...
Page 134 INSP PRE-OPERATION INSPECTION AND MAINTENANCE EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. EC321000 GENERAL INSPECTION AND MAINTENANCE Item Routine Page...
Page 135 INSP INSPECTION ET ENTRETIEN AVANT UTILISATION INSPECTION ET ENTRETIEN AVANT UTILISATION Avant la conduite pour le rodage, l’entraînement ou une course, s’assurer que la machine est en bou état de marche. Avant d’utiliser cette machine, contrôler les points suivants: INSPECTION GENERALE ET ENTRETIEN Partie Routine Page...
Page 136 INSP PRÜFUNG UND WARTUNG VOR DER INBETRIEBNAHME PRÜFUNG UND WARTUNG VOR DER INBETRIEBNAHME Vor dem Einfahren, einer Übungs-oder Rennfahrt, immer die Maschine auf guten Betriebszustand kontrollieren. Vor der Benutzung dieser Maschine sind die folgenden Punkte zu prüfen: ALLGEMEINE PRÜFUNG UND WARTUNG Benennung Vorgang Seite...
Page 137 INSP ISPEZIONE E MANUTENZIONE PRIMA DEL IC320000 ISPEZIONE E MANUTENZIONE PRIMA DEL FUNZIONAMENTO Prima di usarlo per il rodaggio, per allenamento o per una gara, accertarsi che il veicolo sia in buone condi- zioni di funzionamento. Prima di usare questo veicolo, controllare i punti che seguono. IC321000 ISPEZIONE E MANUTENZIONE GENERALI Voce...
Page 138 ENGINE/COOLANT LEVEL INSPECTION/ INSP COOLANT REPLACEMENT EC350000 ENGINE EC351011 COOLANT LEVEL INSPECTION 1 1 , drain Do not remove the radiator cap 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 139 MOTEUR/VERIFICATION DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT/CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT MOTOR/INSPEKTION DES KÜHLMITTELSTANDES/ERNEUERUNG DES KÜHLMITTELS INSP MOTORE/ISPEZIONE DEL LIVELLO DEL LIQUIDO REFRIGERANTE/ SOSTITUZIONE DEL LIQUIDO REFRIGERANTE IC350000 MOTEUR MOTOR MOTORE IC351011 VERIFICATION DU NIVEAU DU INSPEKTION DES ISPEZIONE DEL LIVELLO DEL LIQUIDE DE REFROIDISSEMENT KÜHLMITTELSTANDES LIQUIDO REFRIGERANTE...
Page 140 INSP COOLANT REPLACEMENT Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: 9Coolant drain bolt 1 3. Remove: 9Radiator cap Drain the coolant completely. 4.
Page 141 CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP ERNEUERUNG DES KÜHLMITTELS SOSTITUZIONE DEL LIQUIDO REFRIGERANTE Fare attenzione che il liquido refrige- Prendre garde à ne pas verser de Darauf achten, daß kein Kühlmittel rante non schizzi sulle superfici ver- liquide de refroidissement sur les lackierte Flächen verspritzt...
Page 142 INSP RADIATOR CAP INSPECTION 9 Do not mix more than one type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. 9 Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be handled with special care.
Page 143 VERIFICATION DU BOUCHON DU RADIATEUR INSP INSPEKTION DES KÜHLERDECKELS ISPEZIONE DEL TAPPO DEL RADIATORE 9 Ne pas mélanger plusieurs solutions 9 Niemals 9 Non miscelare più di un tipo di anti- Äthylenglykol-Frost- antigel au glycol d’éthyle contenant schutzmittel Korrosions- gelo a base di glicole etilenico conte- des produits anticorrosion pour schutzzusatz für...
Page 144 RADIATOR CAP OPENING PRESSURE INSPECTION/ INSP COOLING SYSTEM INSPECTION EC356002 RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: 9Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Adapter: YU-33984/90890-01352 NOTE: Apply water on the radiator cap seal. 3 Radiator cap 2.
Page 145 VERIFICATION DE LA PRESSION D’OUVERTURE DU BOUCHON DU RADIATEUR/VERIFICATION DE SYSTEME DE REFROIDISSEMENT INSPEKTION DES KÜHLERDECKELÖFFNUNGSDRUCKS/INSPEKTION DES KÜHLSYSTEMS INSP ISPEZIONE DELLA PRESSIONE DI APERTURA DEL TAPPO DEL RADIATORE/ ISPEZIONE DELL’IMPIANTO DI RAFFREDDAMENTO IC356002 VERIFICATION DE LA PRESSION INSPEKTION KÜHLER- ISPEZIONE DELLA PRESSIONE D’OUVERTURE DU BOUCHON DECKELÖFFNUNGSDRUCKS DI APERTURA DEL TAPPO DEL...
Page 146 INSP CLUTCH ADJUSTMENT NOTE: 9 Do not apply pressure more than specified pressure. 9 Radiator should be filled fully. 4. Inspect: 9Pressure Impossible to maintain the specified pres- sure for 10 seconds Repair. 9Radiator 1 9Radiator hose joint 2 Coolant leakage Repair or replace.
Page 147 REGLAGE DE L’EMBRAYAGE INSP EINSTELLUNG DER KUPPLUNG REGOLAZIONE DELLA FRIZIONE ANMERKUNG: N.B.: NOTA: 9 Ne pas appliquer de pression supé- 9 Non applicare pressione superiore alla 9 Den spezifizierten Druck nicht Über- rieure à la pression spécifiée. schreiten. pressione specificata. 9 Le radiateur doit être entièrement 9 Il radiatore dovrebbe essere completa- 9 Der Kühler sollte vollständig gefüllt...
Page 148 THROTTLE CABLE ADJUSTMENT/ INSP THROTTLE LUBRICATION EC35A001 THROTTLE CABLE ADJUSTMENT 1. Check: 9Throttle grip free play a Out of specification Adjust. Throttle grip free play a a : 3~5 mm (0.12~0.20 in) 2. Adjust: 9Throttle grip free play Throttle grip free play adjustment steps: 9Loosen the locknut 1.
Page 149 REGLAGE DU CABLE D’ACCELERATION/GRAISSAGE DE L’ACCÉLÉRATEUR EINSTELLUNG DES GASSEILES/SCHMIERUNG DES GASSEILS INSP REGOLAZIONE DEL CAVO DELL’ACCELERATORE/ LUBRIFICAZIONE DELLA VALVOLA A FARFALLA IC35A001 REGLAGE DU CABLE EINSTELLUNG DES GASSEILES REGOLAZIONE CAVO D’ACCELERATION 1. Kontrollieren: DELL’ACCELERATORE 9 Spiel am Gasdrehgriff a 1. Contrôler: 1.
Page 150 INSP AIR FILTER CLEANING 3. Install: Throttle cable cap 1 Nm (0.1 m•kg, 0.7 ft•lb) Cap cover EC35G040 AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and dam- age. Never run the engine without the air filter element in place;...
Page 151 NETTOYAGE DU FILTRE A AIR INSP REINIGUNG DES LUFTFILTERS PULITURA DEL FILTRO DELL’ARIA 3. Monter: 3. Einbauen: 3. Installare: 9 Capuchon du câble d’accéléra- 9 Calotta del cavo dell’accelerato- 9 Gasseilkappe teur 1 Nm (0,1 m•kg, 0,7 ft•lb) 1 Nm (0,1 m•kg, 0,7 ft•lb) 1 Nm (0,1 m•kg, 0,7 ft•lb) 9 Kappenabdeckung 9 Couvercle de capuchon...
Page 152 INSP TRANSMISSION OIL LEVEL CHECK 3. Inspect: Air filter element Damage Replace. 4. Apply: Foam-air-filter oil or engine mixing oil To the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping. 5. Install: Filter guide 1 NOTE: Align the projection a on filter guide with the hole b in air filter element.
Page 153 CONTROLE DU NIVEAU DE L’HUILE DE BOITE DE VITESSES INSP PRÜFUNG DES GETRIEBEÖLSTANDES CONTROLLO DEL LIVELLO DELL’OLIO DELLA TRASMISSIONE 3. Examiner: 3. Prüfen: 3. Ispezionare 9 Elément du filtre à air 9 Elemento del filtro dell’aria 9 Luftfilterelement Endommagement Changer. Beschädigung Erneuern.
Page 154 INSP TRANSMISSION OIL REPLACEMENT 3. Check: Transmission oil level Transmission oil level checking steps: Remove the oil check bolt 1. Inspect the oil level. NOTE: Be sure the machine is positioned straight up when inspecting the oil level. Never attempt to remove the oil check bolt just after high speed operation.
Page 155 CHANGEMENT DE L’HUILE DE BOITE DE VITESSES INSP ERNEUERUNG DES GETRIEBEÖLS SOSTITUZIONE DELL’OLIO DELLA TRASMISSIONE 3. Contrôler: 3. Kontrollieren: 3. Controllare: 9 Niveau d’huile de boîte de 9 Livello dell’olio della trasmis- 9 Getriebeölstand vitesses sione Prüfschritte des Getriebeölstan- Passi del controllo del livello des: Procédure de contrôle de niveau dell’olio della trasmissione:...
Page 156 INSP PILOT AIR SCREW ADJUSTMENT 4. Remove: Oil drain bolt 1 Oil filler cap 2 Drain the transmission oil. 5. Install: Aluminum washer Oil drain bolt 1 20 Nm (2.0 m•kg, 14 ft•lb) 6. Fill: Transmission oil Recommended oil: Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil Oil capacity (periodic oil change):...
Page 157 REGLAGE DE LAVIS DE RICHESSE INSP EINSTELLUNG DER LEERLAUFTREGULIERSCHRAUBE REGOLAZIONE DELLA VITE DELL’ARIA PILOTA 4. Déposer: 4. Ausbauen: 4. Togliere: 9 Boulon de vidange d’huile 1 9 Bullone di scarico dell’olio 1 9 Ölablaßschraube 1 9 Bouchon de remplissage d’huile 9 Öleinfüllschraube 2 9 Tappo di riempimento dell’olio Das Getriebeöl ablassen.
Page 158 IDLE SPEED ADJUSTMENT/MUFFLER INSPECTION/ INSP SILENCER FIBER REPLACEMENT EC35M010 IDLE SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Adjust: Idle speed Adjustment steps: Loosen the locknut 1. Turn the throttle stop screw 2 until the engine runs at the lowest possible speed. Tighten the locknut.
Page 159 REGLAGE DU REGIME DE RALENTI/CONTROLE DU SILENCIEUX D’ECHAPPMENT/CHANGEMENT DE FIBRE DU SILENCIEUX EINSTELLUNG DER LEERLAUFDREHZAHL/INSPEKTION DES INSP SCHALLDÄMPFERS/ERNEUERUNG DES SCHALLDÄMPFERFASEREINSATZES REGOLAZIONE DEL NUMERO DI GIRI AL MINIMO/ISPEZIONE DELLA MARMITTA/ SOSTITUZIONE DELLA FIBRA DEL SILENZIATORE IC35M010 REGLAGE REGIME EINSTELLUNG LEERLAUF- REGOLAZIONE DEL NUMERO DI RALENTI DREHZAHL GIRI AL MINIMO...
Page 160 Fully apply Quick gasket ® (Yamaha bond No. 1215) or equivalent as shown. Quick gasket ® ACC-QUICK-GS-KT Yamaha bond No. 1215: 90890-85505 5. Install: Bolt (fiber) 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Silencer 2 Bolt [silencer (front)] 3 12 Nm (1.2 m•kg, 8.7 ft•lb) Bolt [silencer (rear)] 4 7 Nm (0.7 m•kg, 5.1 ft•lb)
Page 161 (Yamaha bond Nr. Applicare ovunque Quick Gasket ® d’étanchéité Quick Gasket ® (Yamaha 1215) oder gleichwertiges Produkt voll (Yamaha Bond n° 1215) o equivalente, Bond n° 1215) ou équivalent comme auftragen, wie dargestellt. come illustrato. illustré. ® Quick Gasket ®...
Page 162 INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING Bleed the brake system if: 9 The system has been disassembled. 9 A brake hose has been loosened or removed. 9 The brake fluid is very low. 9 The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bleed.
Page 163 PARTIE CYCLE/PURGE DE L’AIR DU SYSTEME DE FREINAGE INSP FAHRGESTELL/ENTLÜFTUNG DER BREMSANLAGE TELAIO/ SPURGO DELL’ARIA DALL’IMPIANTO FRENANTE IC360000 PARTIE CYCLE FAHRGESTELL TELAIO PURGE DE L’AIR DU SYSTEME ENTLÜFTUNG DER BREMSANLAGE IC361012 DE FREINAGE SPURGO DELL’ARIA DALL’IMPIAN- TO FRENANTE Die Bremsanlage muß unbedingt in den folgenden Fallen entlüftet werden: Purger le système de freinage si: 9 Nach Demontage und Wiederzu-...
Page 164 INSP FRONT BRAKE ADJUSTMENT NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. j. Add brake fluid to the level line on the reservoir.
Page 165 REGLAGE DE FREIN AVANT INSP EINSTELLUNG DER VORDERRADBREMSE REGOLAZIONE DEL FRENO ANTERIORE ANMERKUNG: N.B.: NOTA: Si la purge est difficile, il peut être Falls das Entlüften schwierig ist, Se lo spurgo risulta difficoltoso, nécessaire de laisser le système du dann muß vielleicht die Bremsanla- può...
Page 166 REAR BRAKE ADJUSTMENT/ INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMENT 1. Check: 9 Brake pedal height a Out of specification Adjust. Brake pedal height a a : 5 mm (0.20 in) 2. Adjust: 9 Brake pedal height Pedal height adjustment steps: 9Loosen the locknut 1.
Page 167 REGLAGE DU FREIN ARRIERE/ VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN AVANT EINSTELLUNG DER HINTERRADBREMSE/ INSP INSPEKTION UND ERNEUERUNG DER VORDERRAD-BREMSBELAGPLATTE REGOLAZIONE DEL FRENO POSTERIORE/ ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE IC364002 REGLAGE DU FREIN ARRIERE EINSTELLUNG DER HINTERRAD- REGOLAZIONE FRENO 1.
Page 168 INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT 9Loosen the pad pin 2. 9Remove the brake hose holder 3 and caliper 4 from the front fork. 9Remove the pad pin and brake pads 5. 9Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end.
Page 169 VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN AVANT INSP INSPEKTION UND ERNEUERUNG DES VORDERRAD-BREMSBELAGPLATTE ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE 9 Desserrer la goupille de plaquette 9 Allentare la spina della pastiglia 9 Bremsbelagstift 2 lösen. 9 Bremsleitungshalter 9 Déposer le support du tuyau de 9 Togliere il supporto del tubo fles- Bremsbelag 4 von der Vorderrad-...
Page 170 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT 9 Install the pad pin plug w. Pad pin plug: 3 Nm (0.3 m•kg, 2.2 ft•lb) 3. Inspect: 9Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: 9Brake lever operation A softy or spongy feeling Bleed brake system.
Page 171 VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN ARRIERE INSP INSPEKTION UND ERNEUERUNG DES HINTERRAD-BREMSBELAGPLATTE ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE 9 Installare il tappo della spina della 9 Bremsbelagplattenstifte w 9 Installer le bouchon de goupille anbrin- pastiglia w.
Page 172 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT 9Remove the pad pin 6 and brake pads 7. 9Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. 9Loosen the bleed screw and push the caliper piston in.
Page 173 VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN ARRIERE INSP INSPEKTION UND ERNEUERUNG DES HINTERRAD-BREMSBELAGPLATTE ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE 9 Déposer la goupille de plaquette 9 Togliere la spina della pastiglia 6 9 Bremsbelagstift 6 und Bremsbelä- 6 et les plaquettes de frein 7.
Page 174 REAR BRAKE PAD INSULATOR INSPECTION INSP BRAKE FLUID LEVEL INSPECTION EC36b000 REAR BRAKE PAD INSULATOR INSPECTION 1. Remove: 9 Brake pad Refer to “REAR BRAKE PAD INSPEC- TION AND REPLACEMENT” section. 2. Inspect: 9 Rear brake pad insulator 1 Damage Replace.
Page 175 VERIFICATION DE L’ISOLANT DE LA PLAQUETTE DE FREIN ARRIERE/VERIFICATION DU NIVEAU DU LIQUIDE DE FREIN INSPEKTION DER ISOLIERUNG DES HINTERRADBREMSBELAGS/INSPEKTION DES INSP BREMSFLÜSSIGKEITSSTANDESS ISPEZIONE DELL’ISOLATORE DELLA PASTIGLIA DEL FRENO POSTERIORE/ISPEZIONE DEL LIVELLO DEL LIQUIDO PER FRENI IC36b000 VERIFICATION DE L’ISOLANT INSPEKTION ISOLIERUNG ISPEZIONE...
Page 176 INSP SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION EC368000 SPROCKETS INSPECTION 1. Inspect: 9 Sprocket teeth a Excessive wear Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set. EC369002 DRIVE CHAIN INSPECTION 1. Remove: 9 Master link clip 9 Joint 1 9 Drive chain 2 2.
Page 177 VERIFICATION DES PIGNONS/VERIFICATION DE LA CHAINE DE TRANSMISSION INSP INSPEKTION DER KETTENRÄDER/INSPEKTION DER ANTRIEBSKETTE ISPEZIONE DEI ROCCHETTI/ ISPEZIONE DELLA CATENA DI TRASMISSIONE IC368000 VERIFICATION DES PIGNONS INSPEKTION DER KETTENRÄDER ISPEZIONE DEI ROCCHETTI 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Dent de pignon a 9 Kettenradzahn a 9 Denti dei rocchetti a Usure excessif Changer.
Page 178 INSP DRIVE CHAIN SLACK ADJUSTMENT 5. Install: 9 Drive chain 1 9 Joint 2 9 Master link clip 3 Be sure to install the master link clip to the direction as shown. a Turning direction 6. Lubricate: 9 Drive chain Drive chain lubricant: SAE 10W-30 motor oil or suitable chain lubricants...
Page 179 REGLAGE DE LA FLECHE DE CHAINE DE TRANSMISSION INSP EINSTELLUNG DES ANTRIEBSKETTENDURCHHANGES REGOLAZIONE DEL GIOCO DELLA CATENA DI TRASMISSIONE 5. Monter: 5. Einbauen: 5. Installare: 9 Chaîne de transmission 1 9 Catena di trasmissione 1 9 Antriebskette 1 9 Raccord 2 9 Verbindung 2 9 Giunto 2 9 Agrafe de l’attache rapide 3...
Page 180 INSP FRONT FORK INSPECTION 3. Adjust: 9 Drive chain slack Drive chain slack adjustment steps: 9 Loosen the axle nut 1 and locknuts 2. 9 Adjust chain slack turning adjusters 3. Turn adjuster 3 3 counter- To tighten clockwise. Turn adjuster 3 3 clockwise To loosen and push wheel forward.
Page 181 VERIFICATION DE LA FOURCHE AVANT INSP INSPEKTION DER VORDERRADGABEL ISPEZIONE DELLA FORCELLA ANTERIORE 3. Régler: 3. Einstellen: 3. Regolare: 9 Flèche de chaîne de transmis- 9 Gioco della catena di trasmis- 9 Antriebskettendurchhang sion sione Einstellschritte des Antriebsket- Procédure de réglage de flèche de Passi della regolazione del gioco tendurchhands: chaîne de transmission:...
Page 182 INSP FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1. Remove: 9 Protector 9 Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.
Page 183 NETTOYAGE DE BAGUE D’ETANCHETTE ET DE JOINT ANTIPOUSSIERE DE FOURCHE AVANT/ REGLAGE DE LA FORCE D’AMORTISSEMENT DE REBOND DE LA FOURCHE AVANT REINIGUNG DER ÖLDICHTUNG UND STAUBDICHTUNG DER VORDERRADGABEL/ INSP EINSTELLUNG DER EXPANSIONS-DÄMPFUNGSKRAFT DER VORDERRADGABEL PULITURA DEL PARAOLIO E DEL PARAPOLVERE DELLA FORCELLA ANTERIORE/ REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELL’ESTENSIONE DELLA FORCELLA ANTERIORE IC36D001 NETTOYAGE...
Page 184 FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT Do not force the adjuster past the minimum or maximum extent of adjustment. The ad- juster may be damaged. Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT...
Page 185 REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION DE LA FOURCHE AVANT INSP EINSTELLUNG DER KOMPRESSIONS-DÄMPFUNGSKRAFT DER VORDERRADGABEL REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELLA COMPRES- SIONE DELLA FORCELLA ANTERIORE Ne pas forcer le régulateur au-delà Den Einsteller nicht über die Mini- Non forzare il dispositivo di regola- du minimum ou du maximum au mum- oder Maximum-Einstellpositi-...
Page 186 INSP REAR SHOCK ABSORBER INSPECTION 9 STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. Standard position: 14 clicks out *12 clicks out *For EUROPE Do not force the adjuster past the minimum or maximum extent of adjustment.
Page 187 VERIFICATION DE L’AMORTISSEUR ARRIERE INSP INSPEKTION DES HINTERRAD-STOSSDÄMPFERS ISPEZIONE DELL’AMMORTIZZATORE POSTERIORE 9 POSITION STANDARD: 9 STANDARD-POSITION: 9 POSIZIONE NORMALE: Das ist die Position, in die aus der C’est la position qui se trouve en È la posizione spostata del numero di voll hineingedrehten Position um die arrière du nombre spécifié...
Page 188 REAR SHOCK ABSORBER SPRING PRELOAD INSP ADJUSTMENT EC36M013 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Remove: 9 Rear frame 3. Loosen: 9 Locknut 1 4. Adjust: 9 Spring preload By turning the adjuster 2.
Page 189 REGLAGE DE LA PRECONTRAINTE DE RESSORT DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER FEDERVORSPANNUNG DES HINTERRAD-STOSSDÄMPFERS INSP REGOLAZIONE DEL PRECARICO DELLA MOLLA DELL’AMMORTIZZATORE POSTERIORE IC36M013 REGLAGE PRECON- EINSTELLUNG DER FEDERVOR- REGOLAZIONE DEL PRECARICO TRAINTE RESSORT SPANNUNG HINTERRAD- DELLA MOLLA DELL’AMMOR- L’AMORTISSEUR ARRIERE STOSSDÄMPFERS TIZZATORE POSTERIORE 1.
Page 190 REAR SHOCK ABSORBER REBOUND DAMPING INSP FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: 9 Rebound damping force By turning the adjuster 1. Stiffer a a Increase the rebound damping force. (Turn the adjuster 1 1 in.) Softer b b Decrease rebound...
Page 191 REGLAGE DE LA FORCE D’AMORTISSEMENT DE REBOND DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER EXPANSIONS-DÄMPFUNGSKRAFT DES INSP HINTERRAD-STOSSDÄMPFERS REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELL’ESTENSIONE DELL’AMMORTIZZATORE POSTERIORE IC36N020 REGLAGE FORCE EINSTELLUNG DER EXPANSIONS- REGOL‹ELLA FORZA DI SMOR- D’AMORTISSEMENT DÄMPFUNGSKRAFT DES HINTER- ZAMENTO DELL’ESTENSIONE REBOND DE L’AMORTISSEUR RAD-STOSSDÄMPFERS D E L L ’...
Page 192 REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: 9 Low compression damping force By turning the adjuster 1. Stiffer a a Increase the low compression damping force. (Turn the ad- juster 1 1 in.) Softer b b Decrease the low compres-...
Page 193 REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION ELEVEE DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER HOHEN KOMPRESSIONS-DÄMPFUNGSKRAFT DES HINTERRADSTOSSDÄMPFFRS INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE IC36c000 REGLAGE FORCE EINSTELLUNG NIEDRIGEN REGOLAZIONE DELLA FORZA D’AMORTISSEMENT DE COM- KOMPRESSIONS-DÄMPFUNGS- DI SMORZAMENTO A BASSA PRESSION BASSE DE L’AMOR- KRAFT...
Page 194 REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: 9 High compression damping force By turning the adjuster 1. Stiffer a a Increase the high compression damping force. (Turn the ad- juster 1 1 in.) Softer b b Decrease the high compres-...
Page 195 REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION ELEVEE DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER HOHEN KOMPRESSIONS-DÄMPFUNGSKRAFT DES HINTERRADSTOSSDÄMPFFRS INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE IC36d000 REGLAGE FORCE EINSTELLUNG DER HOHEN KOM- REGOLAZIONE DELLA FORZA D’AMORTISSEMENT DE COM- PRESSIONS-DÄMPFUNGSKRAFT DI SMORZAMENTO AD ALTA PRESSION ELEVEE DE L’AMOR-...
Page 196 TIRE PRESSURE CHECK/SPOKES INSPECTION AND INSP TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: 9 Tire pressure Out of specification Adjust. Standard tire pressure: 100 kPa (1.0 kg/cm , 15 psi) NOTE: 9 Check the tire while it is cold. 9 Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
Page 197 CONTROLE DE PRESSION DES PNEUS/VERIFICATION ET SERRAGE DES RAYONS/VERIFICATION DE LA ROUE PRÜFUNG DES REIFENDRUCKS/INSPEKTION UND FESTZIEHEN DER INSP SPEICHEN/INSPEKTION DES RADES CONTROLLO DELLA PRESSIONE DEGLI PNEUMATICI/ ISPEZIONE E SERRAGGIO DEI RAGGI/ ISPEZIONE DELLE RUOTE IC36Q000 CONTROLE DE PRESSION DES PRÜFUNG DES REIFENDRUCKS CONTROLLO DELLA PRESSIONE PNEUS...
Page 198 INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: 9 Bearing free play Exist play Replace. EC36U013 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: 9 Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth.
Page 199 VERIFICATION ET REGLAGE DE LA TETE DE FOURCHE INSP INSPEKTION UND EINSTELLUNG DES LENKERKOPFES ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO 2. Examiner: 2. Prüfen: 2. Ispezionare: 9 Jeu de roulement 9 Gioco del cuscinetto 9 Lagerspiel Ily a du jeu Changer.
Page 200 INSP STEERING HEAD INSPECTION AND ADJUSTMENT Ring nut wrench: YU-33975/90890-01403 Ring nut (initial tightening): 38 Nm (3.8 m•kg, 27ft•lb) 9 Loosen the ring nut one turn. 9 Retighten the ring nut using the ring nut wrench. Avoid over-tightening. Ring nut (final tightening): 7 Nm (0.7 m•kg, 5.1 ft•lb) 9 Check the steering shaft by turning it lock to lock.
Page 201 VERIFICATION ET REGLAGE DE LA TETE DE FOURCHE INSP INSPEKTION UND EINSTELLUNG DES LENKERKOPFES ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO Clé pour écrou annulaire: Ringmutterschlüssel: Chiave per ghiera: YU-33975/90890-01403 YU-33975/90890-01403 YU-33975/90890-01403 Ecrou annulaire (serrage Ghiera Ringmutter initial): (serraggio iniziale): (anfängliches 38 Nm (3,8 m•kg, 27 ft•lb) 38 Nm (3,8 m•kg, 27 ft•lb)
Page 202 INSP LUBRICATION EC36a042 LUBRICATION Å Use Yamaha cable lube or equivalent on To ensure smooth operation of all components, these areas. lubricate your machine during setup, after break- ı Use SAE10W-30 motor oil or suitable chain in, and after every race.
Page 203 9 Gasseilende 0 Estremità del cavo della frizione 0 Extrémités des câbles d’embrayage 0 Kupplungsseilenden A Usare lubrificante per cavi Yamaha o A Mettre du lubrifiant Yamaha pour A Yamaha Seilung-Schmiermittel oder equivalente su queste zone. câbles, ou équivalent sur ces parties.
Page 204 INSP ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: 9 Spark plug 2. Inspect: 9 Electrode 1 Wear/Damage Replace. 9 Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color Check the engine condition.
Page 205 PARTIE ELECTRIQUE/VERIFICATION DE LA BOUGIE INSP ELEKTRISCHE EINRICHTUNGEN/INSPEKTION DER ZÜNDKERZE PARTE ELETTRICA/ ISPEZIONE DELLA CANDELA IC370000 PARTIE ELECTRIQUE ELEKTRISCHE PARTE ELETTRICA VERIFICATION DE LA BOUGIE EINRICHTUNGEN IC371001 1. Déposer: ISPEZIONE DELLA CANDELA INSPEKTION DER ZÜNDKERZE 9 Bougie 1. Togliere: 1. Ausbauen: 9 Candela 2.
Page 206 INSP IGNITION TIMING CHECK EC372051 IGNITION TIMING CHECK 1. Remove: 9 Cylinder head Refer to “CYLINDER HEAD, CYLINDER AND PISTON” section in the CHAPTER 4. 9 Crankcase cover (left) 2. Attach: 9 Dial gauge 1 9 Dial gauge stand 2 Dial gauge: YU-3097/90890-01252 Stand:...
Page 207 CONTROLE ET REGLAGE DE L’AVANCE A L’ALLUMAGE INSP PRÜFUNG UND EINSTELLUNG DER ZÜNDZEITPUNKT CONTROLLO DELLA MESSA IN FASE DELL’ACCENSIONE IC372051 CONTROLE ET REGLAGE DE PRÜFUNG EINSTELLUNG CONTROLLO DELLA MESSA IN L’AVANCE A L’ALLUMAGE DER ZÜNDZEITPUNKT FASE DELL’ACCENSIONE 1. Déposer: 1. Ausbauen: 1.
Page 208 INSP IGNITION TIMING CHECK 7. Adjust: 9 Ignition timing Adjustment steps: 9 Loosen the screws (stator) 1. 9 Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator. 9 Tighten the screws (stator). Screw (stator): 8 Nm (0.8 m•kg, 5.8 ft•lb) 3-40...
Page 209 CONTROLE ET REGLAGE DE L’AVANCE A L’ALLUMAGE INSP PRÜFUNG UND EINSTELLUNG DER ZÜNDZEITPUNKT CONTROLLO DELLA MESSA IN FASE DELL’ACCENSIONE 7. Régler: 7. Einstellen: 7. Regolare: 9 Avance à l’allumage 9 Messa in fase dell’accensione 9 Zündzeitpunkt Procédure de réglage: Einstellschritte: Passi della regolazione: 9 Desserrer les vis (stator) 1.
Page 210 SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS 7 Nm (0.7 m•kg, 5.1 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb)
Page 211 SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX SITZ, KRAFTSTOFFTANK UND SEITENDECKEL SELLA, SERBATOIO DEL CARBURANTE E COPERTURE LATERALI MOTEUR SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX 1 Dépose du selle 2 Dépose du réservoir à essence Etendue de dépose: 3 Dépose des couvercles latéraux 4 Dépose de la plaque d’immatriculation Etendue de dépose Ordre...
Page 212 SEAT, FUEL TANK AND SIDE COVERS EC4R3000 REMOVAL POINTS EC413101 Side cover 1. Remove: 9 Side cover (left and right) 1 Be sure to remove the seat before remov- ing the side cover. If you remove the side cover with force without removing the seat, 2 2 (on the inside) may contact the panel the air cleaner case and come off.
Page 213 SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX SITZ, KRAFTSTOFFTANK UND SEITENDECKEL SELLA, SERBATOIO DEL CARBURANTE E COPERTURE LATERALI IC4R3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC413101 Couvercle latéral Copertura laterale Seitendeckel 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Couvercle latéral (gauche et 9 Copertura laterale (sinistra e 9 Seitendeckel (Links...
Page 214 EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER 7 Nm (0.7 m•kg, 5.1 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 1 Silencer removal 2 Exhaust pipe removal Extent of removal: Extent of removal...
Page 215 TUYAU D’ECHAPPEMENT ET SILENCIEUX AUSPUFFROHR UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE TUYAU D’ECHAPPEMENT ET SILENCIEUX 1 Dépose du silencieux 2 Dépose du tuyau déchappement Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU TUYAU DéCHAPPEMENT ET DU SILENCIEUX Préparation...
Page 216 RADIATOR EC450001 RADIATOR 1 Nm (0.1 m•kg, 0.7 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 1 Radiator removal Extent of removal: Extent of removal Order Part name Q’ty Remarks RADIATOR REMOVAL Preparation for Drain the coolant. Refer to “COOLANT REPLACEMENT“ removal section in the CHAPTER 3.
Page 217 RADIATEUR KÜHLER RADIATORE RADIATEUR 1 Dépose du radiateur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU RADIATEUR Vidanger le liquide de refroidissement. Se reporter à la section “CHANGEMENT DU Préparation LIQUIDE DE REFROIDISSEMENT” du pour la dépose CHAPITRE 3.
Page 218 RADIATOR EC456000 HANDLING NOTE Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious in- jury. When the engine has cooled, open the ra- diator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counter-...
Page 219 RADIATEUR KÜHLER RADIATORE IC456000 REMARQUES HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO CONCERNANT LA MANIPULATION Non togliere il tappo del radiatore Wenn der Motor und der Kühler heiß sind, darf niemals der Künler- quando il motore e il radiatore sono deckel entfernt werden. Brühend caldi.
Page 220 RADIATOR EC455000 ASSEMBLY AND INSTALLATION EC445341 Radiator 1. Install: 9Radiator breather hose 1 9Radiator hose 3 2 1 Nm (0.1 m•kg, 0.7 ft•lb) 9Radiator hose 1 3 1 Nm (0.1 m•kg, 0.7 ft•lb) To radiator (right) 4. NOTE: Install the radiator hose 3 with its shorter pro- truding length a from the protector 5 on the ra- diator side.
Page 221 RADIATEUR KÜHLER RADIATORE IC455000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E Kühler MONTAGE INSTALLAZIONE 1. Einbauen: Radiateur IC455341 9 Kühler-Belüftungsschlauch 1 1. Monter: Radiatore 9 Kühlerschlauch 3 2 9 Tuyau de renifard de radiateur 1. Installare: 9 Sfiato del radiatore 1 1 Nm (0,1 m•kg, 0,7 ft•lb) 9 Tuyau de radiateur 3 2 9 Manicotto flessibile del radiato-...
Page 222 CARBURETOR AND REED VALVE EC460000 CARBURETOR AND REED VALVE 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 1 Carburetor removal 2 Reed valve removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR AND REED VALVE REMOVAL Preparation for Fuel tank...
Page 223 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA CARBURATEUR ET SOUPAPE FLEXIBLE 1 Dépose du carburateur 2 Dépose de la soupape flexible Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU CARBURATEUR ET DE LA SOUPAPE FLEXIBLE Réservoir à...
Page 224 CARBURETOR AND REED VALVE EC468000 CARBURETOR DISASSEMBLY 1 Carburetor disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Mixing chamber top Throttle valve Refer to “REMOVAL POINTS”. Needle holder Jet needle Float chamber Needle jet cover Float pin Float Valve seat...
Page 225 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA DEMONTAGE DU CARBURATEUR 1 Démontage du carburateur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEMONTAGE DU CARBURATEUR Haut de chambre de mélange Boisseau Se reporter à...
Page 226 CARBURETOR AND REED VALVE EC466030 HANDLING NOTE Do not disassemble the venturi block 1 1 and main nozzle 2 2 because it will cause a drop in carburetor performance. EC463000 REMOVAL POINTS EC463110 Throttle valve 1. Remove: 9 Throttle valve 1 9 Ring 2 9 Spring (throttle valve) 3 9 Mixing chamber top 4...
Page 227 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC466030 REMARQUES HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO CONCERNANT LA MANIPULATION Venturiblock 1 1 und Hauptdüse 2 2 Non smontare il blocco del diffusore 1 1 e l'ugello principale 2 2 perché nicht ausbauen, weil dadurch ein Leistungsabfall beim...
Page 228 CARBURETOR AND REED VALVE 2. Inspect: 9 Main jet 1 9 Main jet holder 2 9 Pilot jet 3 Contamination Clean. NOTE: 9 Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. 9 Never use a wire.
Page 229 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 2. Examiner: 2. Prüfen: 2. Ispezionare: 9 Gicleur principal 1 9 Getto principale 1 9 Hauptdüse 1 9 Support de gicleur principal 2 9 Hauptdüsenhalter 2 9 Supporto del getto principale 2 9 Gicleur de ralenti 3 9 Leerlaufdüse 3 9 Getto pilota 3...
Page 230 CARBURETOR AND REED VALVE EC464A00 Filter 1. Inspect: 9Filter 1 Damage Replace. NOTE: Inspect the filter as it is assembled to the carbu- retor. Do not remove the filter except when replacing it. EC464802 Fuel level 1. Measure: 9Fuel level a Out of specification Adjust.
Page 231 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC464A00 Filter Filtro Filtre 1. Prüfen: 1. Ispezionare: 1. Examiner: 9 Filter 1 9 Il filtro 1 9 Filtre 1 Beschädigung Erneuern. Danni Sostituirlo. Endommagement Changer. ANMERKUNG: NOTA: N.B.: Filter beim Einbau in den Vergaser Ispezionare il filtro così...
Page 232 CARBURETOR AND REED VALVE EC464600 Float 1. Inspect: 9Float 1 Damage Replace. EC464701 Reed valve 1. Measure: 9Reed valve bending a Out of specification Replace. Reed valve bending limit: 0.2 mm (0.008 in) 9Valve stopper height b Out of specification Adjust stopper/ Replace valve stopper.
Page 233 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC464600 Flotteur Schwimmer Galleggiante 1. Examiner: 1. Prüfen: 1. Ispezionare 9 Galleggiante 1 9 Flotteur 1 9 Schwimmer 1 Endommagement Changer. Beschädigung Erneuern. Danni Sostituirlo. IC464701 Soupape flexible Zungenventil Valvola a lamella 1.
Page 234 CARBURETOR AND REED VALVE 2. Install: 9Reed valve assembly 1 9Reed valve spacer 2 NOTE: Install the reed valve spacer with its wider con- tact surface side a to the right. 3. Install: 9Carburetor joint 1 9Bolt (carburetor joint) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) EC4652C2 Carburetor...
Page 235 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 2. Monter: 2. Einbauen: 2. Installare: 9 Ens. soupape flexible 1 9 Gruppo valvola a lamella 1 9 Zungenventil 1 9 Rondelle d’espacement de sou- 9 Zungenventil-Abstandhalter 2 9 Distanziale per valvola a lamel- pape à...
Page 236 CARBURETOR AND REED VALVE 3. Install: 9Main jet holder 1 9Main jet 2 9Pilot jet 3 9Valve seat 4 9Screw (valve seat) 5 4. Install: 9Needle valve 1 9Float 2 9Float pin 3 9Screw (float pin) 4 9Needle jet cover 5 NOTE: 9After installing the needle valve to the float, in- stall them to the carburetor.
Page 237 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 3. Monter: 3. Einbauen: 3. Installare: 9 Support de gicleur principal 1 9 Supporto del getto principale 1 9 Hauptdüsenhalter 1 9 Gicleur principal 2 9 Hauptdüse 2 9 Getto principale 2 9 Gicleur de ralenti 3 9 Leerlanfdüse 3...
Page 238 CARBURETOR AND REED VALVE 7. Install: 9Throttle cable 1 9Mixing chamber top 2 9Spring (throttle valve) 3 9Ring 4 9Throttle valve 5 NOTE: 9While compressing the spring, connect the throttle cable. 9Align the projection a on the ring with the groove b in the needle holder 6.
Page 239 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 7. Monter: 7. Einbauen: 7. Installare: 9 Câble d’acélérateur 1 9 Cavo dell’acceleratore 1 9 Gasseil 1 9 Haut de chambre de mélange 2 9 Mischkammer-Oberteil 2 9 Parte superiore del diffusore 2 9 Ressort (boisseau) 3 9 Feder (Drosselventil) 3 9 Molla (valvola regolatrice del...
Page 240 CARBURETOR AND REED VALVE 2. Tighten: 9Screw (air filter joint) 1 9Screw (carburetor joint) 2 3. Clamp: 9Air vent hose 1 9Overflow hose 2 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 4. Adjust: 9 Idle speed Refer to “IDLE SPEED ADJUSTMENT” section in the CHAPTER 3.
Page 241 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 2. Serrer: 2. Festziehen: 2. Serrare: 9 Vis (raccord du filtre à air) 1 9 Vite (giunto del filtro dell’aria) 9 Schraube (Luftfilterverbindung) 9 Vis (raccord du carburateur ) 2 9 Schraube 9 Vite (giunto del carburatore) 2 (Vergaserverbin-...
Page 242 CYLINDER HEAD, CYLINDER AND PISTON EC470000 CYLINDER HEAD, CYLINDER AND PISTON EC478000 CYLINDER HEAD AND CYLINDER 34 Nm (3.4 m•kg, 24 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 28 Nm (2.8 m•kg, 20 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb)
Page 243 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE CULASSE, CYLINDRE ET PISTON CULASSE ET CYLINDRE 1 Dépose de la culasse 2 Dépose du cylindre Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA CULASSE ET DU CYLINDRE...
Page 244 CYLINDER HEAD, CYLINDER AND PISTON EC478100 PISTON AND POWER VALVE 4 Nm (0.4 m•kg, 2.9 ft•lb) 8 Nm (0.8 m•kg, 5.8 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Piston and piston ring removal 2 Power valve removal Extent of removal: Extent of removal...
Page 245 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE PISTON ET CLAPET DE PUISSANCE 1 Dépose du piston et segment 2 Dépose du clapet puissance Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU PISTON ET CLAPET DE PUISSANCE...
Page 246 CYLINDER HEAD, CYLINDER AND PISTON EC473000 REMOVAL POINTS EC473210 Push rod 1. Remove: 9Bolt (push rod) 1 9Push rod 2 NOTE: Set the collar 3 included in owner’s tool kit to remove the bolt (push rod). EC473401 Piston and piston ring 1.
Page 247 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC473000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC473210 Champignon de débrayage Asta di spinta Schubstange 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Boulon 9 Bullone (asta di spinta) 1 9 Schraube (Schubstange) 1 (champignon débrayage) 1...
Page 248 CYLINDER HEAD, CYLINDER AND PISTON EC474000 INSPECTION EC474101 Cylinder head 1. Remove: 9Carbon deposits Use a rounded scraper 1. NOTE: Take care to avoid damaging the spark plug threads. Do not use a sharp instrument. Avoid scratching the aluminum. 2. Inspect: 9Cylinder head water jacket Crust of minerals/Rust Remove.
Page 249 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474000 VERIFICATION INSPEKTION ISPEZIONE IC474101 Culasse Testa cilindro Zylinderkopf 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Depôts de carbone 9 Depositi carboniosi 9 Ölkohleablagerungen Utiliser le grattoir arrondi 1. Einen abgerundeten Schaber Usare un raschietto arrotondato 1 verwenden.
Page 250 CYLINDER HEAD, CYLINDER AND PISTON 2. Inspect: 9Cylinder inner surface Score marks Repair or replace. Use #400~600 grit wet sandpaper. Do not rebore the cylinder. 3. Measure: 9Cylinder bore “C” Use cylinder gauge 1. Out of limit Replace. NOTE: Measure the cylinder bore “C” in parallel (A, B, C) to and at right angles to the crankshaft (a, b).
Page 251 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 2. Examiner: 2. Prüfen: 2. Ispezionare: 9 Surface interne du cylindre 9 Superficie interna del cilindro 9 Innenfläche des Zylinders Marques de rayures Réparer Freßmarken Reparieren oder Rigature Ripararla o sostituir- ou changer.
Page 252 CYLINDER HEAD, CYLINDER AND PISTON EC474402 Piston pin and small end bearing 1. Inspect: 9Piston pin 9Small end bearing Signs of heat discoloration Replace. 2. Measure: 9Piston pin outside diameter Use micrometer 1. Out of limit Replace. Piston pin outside diameter: Standard <Limit>...
Page 253 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474402 Axe de piston et coussinet de pied de Kolbenbolzen und Pleuelfußlager Spinotto e cuscinetto dell’estremità bielle 1. Prüfen: piccola 9 Kolbenbolzen 1. Examiner: 1. Ispezionare: 9 Spinotto 9 Axe de piston 9 Pleuelfußlager 9 Coussinet de pied de bielle...
Page 254 CYLINDER HEAD, CYLINDER AND PISTON EC474502 Piston ring 1. Install: 9Piston ring Into the cylinder. Push the ring with the piston crown. 2. Measure: 9End gap Use a thickness gauge 1. Out of limit Replace. Ring end gap (installed): Standard <Limit>...
Page 255 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474502 Segment Kolbenring Fascia elastica 1. Monter: 1. Ausbauen: 1. Installare: 9 Fascia elastica 9 Segment 9 Kolbenring Dans le cylindre. In Zylinder. Nel cilindro. Pousser le segment avec la Den Kolbenring mit dem Kol- Spingere la fascia con la corona calotte du piston.
Page 256 CYLINDER HEAD, CYLINDER AND PISTON Piston clearance: Standard <Limit> 0.040~0.045 mm 0.1 mm (0.0016~0.0018 in) (0.004 in) EC474700 Combination of piston and cylinder 1. Check: 9Cylinder mark a Cylinder mark a a Cylinder size 54.000~54.002 mm (2.1260~2.1261 in) 54.004~54.006 mm (2.1261~2.1262 in) 54.008~54.010 mm (2.1263~2.1264 in)
Page 257 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE Kolbenspiel: Jeu de piston: Gioco del pistone: Standard <Limite> Standard <Grenze> Valore normale <Limite> 0,040~0,045 mm 0,1 mm 0,040~0,045 mm 0,1 mm 0,040~0,045 mm 0,1 mm (0,0016~0,0018 in) (0,004 in) (0,0016~0,0018 in) (0,004 in)
Page 258 CYLINDER HEAD, CYLINDER AND PISTON EC474830 Power valve 1. Inspect: 9Power valve 1,2 1 Wear/Damage Replace. Carbon deposits Remove. 9Link lever 2 9Valve shaft 3 9Collar 4 Wear/Damage Replace. 9Spring 5 Broken Replace. EC474901 Power valve hole on cylinder 1. Remove: 9 Carbon deposits From power valve hole surface a.
Page 259 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474830 Clapet de puissance Leistungsventil Valvola di potenza 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Valvola di potenza 1,2 1 9 Clapet de puissance 1,2 1 9 Leistungsventil 1,2 1 Usure/endommagement Rem- Abnutzung/Eeschädigung Usura/Danni Sostituirla.
Page 260 CYLINDER HEAD, CYLINDER AND PISTON 2. Install: 9Spring 1 9Link lever 2 9Collar 3 9Valve shaft 4 9Bolt (link lever) 5 4 Nm (0.4 m•kg, 2.9 ft•lb) NOTE: 9Install the spring to the link lever, and then to the cylinder. 9Install the spring with its stopper portion a fac- ing inward.
Page 261 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 2. Monter: 2. Einbauen: 2. Installare: 9 Ressort 1 9 Molla 1 9 Feder 1 9 Levier articulé 2 9 Verbindungshebel 2 9 Leva del biscottino 2 9 Collerette 3 9 Hülse 3 9 Piattello 3...
Page 262 CYLINDER HEAD, CYLINDER AND PISTON EC475233 Piston ring and piston 1. Install: 9Piston ring 1 NOTE: 9Take care not to scratch the piston or damage the piston ring. 9Align the piston ring gap with the pin 2. 9After installing the piston ring, check the smooth movement of it.
Page 263 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC475232 Segment et piston Kolbenring und Kolben Fascia elastica e pistone 1. Monter: 1. Ausbauen: 1. Installare: 9 Fascia elastica 1 9 Segment 1 9 Kolbenring 1 ANMERKUNG: N.B.: NOTA:...
Page 264 CYLINDER HEAD, CYLINDER AND PISTON EC4753A1 Cylinder head and cylinder 1. Apply: 9Engine oil To piston 1, piston ring 2 and cylinder surface. 2. Install: 9Cylinder 1 Make sure the piston ring is properly posi- tioned. Install the cylinder with one hand while compressing the piston ring with the other hand.
Page 265 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC4753A1 Culasse et cylindre Zylinderkopf und Zylinder Testa cilindro e cilindro 1. Appliquer: 1. Auftragen: 1. Applicare: 9 Olio per motori 9 Huile du moteur 9 Motoröl Sul pistone 1, sulla fascia ela- Sur le piston 1, le segment 2 Auf Kolben 1, Kolbenring 2...
Page 266 CYLINDER HEAD, CYLINDER AND PISTON 5. Install: 9Gasket (power valve housing) 9Power valve housing 1 9Bolt (power valve housing) 2 5 Nm (0.5 m•kg, 3.6 ft•lb) 6. Install: 9O-ring 1 NOTE: Apply the lithium soap base grease on the O- rings.
Page 267 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 5. Monter: 5. Einbauen: 5. Installare: 9 Joint (boîtier de clapet de puis- 9 Guarnizione (corpo della valvo- 9 Dichtung (Leistungsventil- sance) gehäuse) la di potenza) 9 Boîtier de chapet de puissance 9 Leistungsventilgehäuse 1 9 Corpo della valvola di potenza 9 Schraube...
Page 268 CLUTCH AND PRIMARY DRIVEN GEAR EC490000 CLUTCH AND PRIMARY DRIVEN GEAR EC498000 CLUTCH PLATE AND FRICTION PLATE 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Clutch plate and friction plate removal Extent of removal: Extent of removal Order Part name Q’ty...
Page 269 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO EMBRAYAGE ET PIGNON MENE PRIMAIRE DISQUE D’EMBRAYAGE ET DISQUE DE FRICTION 1 Dépose du disque d’embrayage et du disque de friction Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 270 CLUTCH AND PRIMARY DRIVEN GEAR EC498100 PRIMARY DRIVEN GEAR 80 Nm (8.0 m•kg, 58 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 1 Primary driven gear removal 2 Push lever removal Extent of removal: Extent of removal Order Part name Q’ty Remarks PRIMARY DRIVEN GEAR REMOVAL...
Page 271 EMBRAYAGE ET PISGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO PIGNON MENE PRIMAIRE 1 Dépose du pignon mené primaire Etendue de dépose: 2 Dépose du levier poussée Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU PIGNON MENE PRIMAIRE ü...
Page 272 CLUTCH AND PRIMARY DRIVEN GEAR EC493000 å å REMOVAL POINTS EC483211 Clutch boss 1. Remove: 9Nut 1 9Lock washer 2 9Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4, 5 to hold the clutch boss. ∫...
Page 273 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC493000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC483211 Noix d’embrayage Mozzo della frizione Kupplungsnabe 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Ecrou 1 9 Dado 1 9 Mutter 1 9 Rondelle-frein 2 9 Rosetta di sicurezza 2...
Page 274 CLUTCH AND PRIMARY DRIVEN GEAR EC484500 Friction plate 1. Measure: 9Friction plate thickness Out of specification Replace friction plate as a set. Measure at all four points. Friction plate thickness: Standard <Limit> 2.9~3.1 mm 2.8 mm (0.114~0.122 in) (0.110 in) EC484600 Clutch plate 1.
Page 275 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC484500 Disque de friction Reibscheibe Disco di innesto 1. Mesurer: 1. Messen: 1. Misurare: 9 Spessore del disco di innesto 9 Epaisseur de disque de friction 9 Reibscheibendicke Hors-spécification Changer Abweichung von Spezifikation Fuori...
Page 276 CLUTCH AND PRIMARY DRIVEN GEAR EC495000 ASSEMBLY AND INSTALLATION EC495240 Clutch 1. Install: 9Thrust plate [ f 36 mm (1.42 in)] 1 9Spacer 2 9Bearing 3 9Primary driven gear 4 NOTE: Apply the transmission oil on the spacer, bearing and primary driven gear inner circumference. 2.
Page 277 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC495000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E Kupplung MONTAGE INSTALLAZIONE 1. Einbauen: Embrayage IC495240 9 Druckscheibe [ f 36 mm (1,42 Frizione 1. Monter: in)] 1 9 Plaque de botée [ f 36 mm (1,42 1.
Page 278 CLUTCH AND PRIMARY DRIVEN GEAR 5. Install: 9Friction plate 1 1 9Clutch plate 2 9Friction plate 2 3 NOTE: 9Install the clutch plates and friction plates alter- nately on the clutch boss, starting with a friction plate and ending with a friction plate. 9Use the friction plates 1 for the first and final while paying attention to the difference in sur- face pattern.
Page 279 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO 5. Monter: 5. Einbauen: 5. Installare: 9 Disque de friction 1 1 9 Disco di innesto 1 1 9 Reibscheibe 1 1 9 Disque d’embrayage 2 9 Kupplungsscheibe 2 9 Disco della frizione 2 9 Disque de friction 2 3 9 Reibscheibe 2 3...
Page 280 CLUTCH AND PRIMARY DRIVEN GEAR 9. Install: 9Gasket (clutch cover) 1 NOTE: Position the rack a on the push rod backward. 10. Install: 9 Clutch cover 1 9 Bolt (clutch cover) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the bolts in stage, using a crisscross pattern.
Page 281 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO 9. Monter: 9. Einbauen: 9. Installare: 9 Joint (couvercle d’embrayage) 9 Guarnizione (coperchio della 9 Dichtung (Kupplungsdeckel) 1 frizione) 1 ANMERKUNG: N.B.: NOTA: Placer le support a en arrière sur la Posizionare la cremagliera a sull’asta Die Zahnstange a und die Schub- tige poussoir.
Page 282 CLUTCH AND PRIMARY DRIVEN GEAR 4. Install: 9Plain washer 1 9 Circlip 2 4-37...
Page 283 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO 4. Monter: 4. Einbauen: 4. Installare: 9 Rondelle ordinaire 1 9 Rossetta 1 9 Beilegescheibe 1 9 Circlip 2 9 Sprengring 2 9 Anello elastico di arresto 2 4-37...
Page 284 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C0000 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8000 PRIMARY DRIVE GEAR 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) 1 Primary drive gear removal Extent of removal: Extent of removal Order...
Page 285 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE PIGNON DE TRANSMISSION PRIMAIRE 1 Dépose du pignon de transmission primaire Etendue de dépose: Etendue de dépose...
Page 286 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8100 KICK AXLE AND SHIFT SHAFT 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Kick axle and kick idle gear removal Extent of removal: 2 Shift shaft and stopper lever removal Extent of removal...
Page 287 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR 1 Dépose de l’axe de démarreur au pied et du pignon de renvoi de démarreur au pied Etendue de dépose: 2 Dépose de l’arbre de sélecteur et du levier de butée Etendue de dépose...
Page 288 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C3000 REMOVAL POINTS EC483111 Primary drive gear 1. Loosen: 9Bolt (primary drive gear) 1 NOTE: Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3. EC4B3101 Kick axle assembly 1.
Page 289 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4C3000 PUNTI DI RIMOZIONE POINTS DE DEPOSE AUSBAUPUNKTE IC483111 Ingranaggio conduttore primario Pignon de transmission primaire Primärantriebszahnrad 1.
Page 290 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4B4300 Kick gear clip 1. Measure: 9Kick clip friction force Out of specification Replace. Use a spring gauge 1. Kick clip friction force: 0.8~1.2 kg (1.8~2.6 lb) EC4B4400 Shift shaft 1. Inspect: 9Shift shaft 1 Bend/Damage Replace.
Page 291 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4B4300 Agrafe de pignon de démarreur au Kickstarter-Zahnradklemme Fermaglio a graffa dell’ingranaggio della pedivella pied 1.
Page 292 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C5000 ASSEMBLY AND INSTALLATION EC4C5120 Stopper lever 1. Install: 9Torsion spring 1 9Stopper lever 2 9Spacer 3 9Bolt (stopper lever) 4 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: 9Align the stopper lever roller with the slot on segment.
Page 293 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4C5000 MONTAGGIO E REMONTAGE ET MONTAGE UND EINBAU INSTALLAZIONE MONTAGE IC4C5120 Anschlaghebel Leva di fermo Levier de butée 1.
Page 294 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 4. Install: 9Bolt (shift guide) 1 10 Nm (1.0 m•kg, 7.2 ft•lb) EC4C5301 Shift shaft 1. Install: 9Roller 1 9 Shift shaft 2 NOTE: Apply the transmission oil on the roller and shift shaft.
Page 295 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO 4. Monter: 4. Einbauen: 4. Installare: 9 Boulon (guide de sélecteur) 1 9 Bullone (guida del cambio) 1 9 Schraube (Schaltführung) 1 10 Nm (1,0 m•kg, 7,2 ft•lb) 10 Nm (1,0 m•kg, 7,2 ft•lb)
Page 296 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 4. Hook: 9Torsion spring 1 NOTE: Turn the torsion spring clockwise and hook into the proper hole a in the crankcase. EC4C5402 Kick idle gear 1. Install: 9Circlip 1 9Kick idle gear 2 9Plain washer 3 NOTE: 9Apply the transmission oil on the kick idle gear...
Page 297 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO 4. Crocher: 4. Haken: 4. Agganciare: 9 Ressort de torsion 1 9 Molla di torsione 1 9 Torsionsfeder 1 N.B.: NOTA:...
Page 298 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 5. Install: 9Crankcase cover (right) 1 NOTE: 9Position the rack a on the push rod backward. 9Mesh the governor gear 2, and impeller shaft gear 3 with primary drive gear 4. 6. Install: 9Bolt [crankcase cover (right)] 1 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE:...
Page 299 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO 5. Monter: 5. Einbauen: 5. Installare: 9 Couvercle de carter (droit) 1 9 Copertura del carter (destra) 1 9 Kurbelgenhäusedeckel (Rechts) 1 N.B.:...
Page 300 YPVS GOVERNOR EC4K0000 YPVS GOVERNOR 5 Nm (0.5 m•kg, 3.6 ft•lb) 1 YPVS governor removal and disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks YPVS GOVERNOR REMOVAL Preparation for Crankcase cover (right) Refer to “KICK AXLE, SHIFT SHAFT AND removal PRIMARY DRIVE GEAR”...
Page 301 REGULATEUR YPVS YPVS REGLER REGOLATORE YPVS REGULATEUR YPVS 1 Dépose et démontage du régulateur YPVS Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU REGULATEUR YPVS Préparation pour la dépose Couvercle de carter (droit) Se reporter à la section “AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION”.
Page 302 YPVS GOVERNOR EC4K3000 REMOVAL POINTS EC4K3100 Governor 1. Remove: 9Dowel pin 1 NOTE: While compressing the spring, remove the dowel pin. EC4K4000 INSPECTION EC4K4100 Governor groove 1. Inspect: 9Plain washer 1 9Collar 2 Wear/Damage Replace. EC4K4200 Bearing 1. Inspect: 9Thrust bearing 1 9Plain washer 2 Wear/Damage Replace.
Page 303 REGULATEUR YPVS YPVS REGLER REGOLATORE YPVS IC4K3000 PUNTI DI RIMOZIONE POINTS DE DEPOSE AUSBAUPUNKTE IC4K3100 Regolatore Régulateur Regler 1. Togliere: 1. Déposer: 1. Ausbauen: 9 Perno di riferimento 1 9 Goujon 1 9 Paßstift 1 NOTA: N.B.: ANMERKUNG: Togliere il perno di riferimento compri- Déposer le goujon tout en comprimant Die Feder zusammendrüken, und den mendo la molla.
Page 304 YPVS GOVERNOR 2. Install: 9Ball 1 9Retainer 2 To governor shaft 3. NOTE: Apply the transmission oil on the retainer and ball. 3. Install: 9Dowel pin 1 NOTE: 9While compressing the spring, install the dowel pin. 9Make sure the dowel pin fits into the groove a in the retainer.
Page 305 REGULATEUR YPVS YPVS REGLER REGOLATORE YPVS 2. Monter: 2. Einbauen: 2. Installare: 9 Bille 1 9 Sfera 1 9 Kugel 1 9 Retenue 2 9 Halter 2 9 Fermo 2 Sur l’arbre du régulateur 3. Zur Reglerachse 3 Sull’albero del regolatore 3. N.B.: ANMERKUNG: NOTA:...
Page 306 WATER PUMP EC4G0000 WATER PUMP 14 Nm (1.4 m•kg, 10 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Impeller shaft removal 2 Oil seal removal Extent of removal: Extent of removal Order Part name Q’ty Remarks WATER PUMP DISASSEMBLY...
Page 307 POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA POMPE A EAU 1 Dépose du pignon d’axe de turbine 2 Dépose de bague d’étanchéité Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA POMPE A EAU Préparation pour la dépose Couvercle de carter (droit) Se reporter à...
Page 308 WATER PUMP EC4G3000 REMOVAL POINTS EC4G3110 Impeller shaft 1. Remove: 9Impeller 1 9Plain washer 2 9Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the im- peller. EC4G3210 Oil seal NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as...
Page 309 POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA IC4G3000 PUNTI DI RIMOZIONE POINTS DE DEPOSE AUSBAUPUNKTE IC4G3110 Albero del girante Axe de turbine Flügelradwelle 1. Togliere: 1. Déposer: 1. Ausbauen: 9 Girante 1 9 Turbine 1 9 Flügelrad 1 9 Rosetta 2 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Albero del girante 3...
Page 310 WATER PUMP EC444300 Impeller shaft gear 1. Inspect: 9Gear teeth a Wear/Damage Replace. EC4H4600 Bearing 1. Inspect: 9Bearing 1 Rotate inner race with a finger. Rough spot/Seizure Replace. EC444400 Oil seal 1. Inspect: 9Oil seal 1 Wear/Damage Replace. EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111 Oil seal 1.
Page 311 POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA IC444300 Pignon d’axe de turbine Flügelradwellenzahnrad Ingranaggio dell’albero del girante 1. Examiner: 1. Ispezionare: 1. Prüfen: 9 Denti dell’ingranaggio a 9 Dents a 9 Zähne a Usure/endommagement Usura/Danni Sostituirli. Abnutzung/Beschädigung Changer. Erneuern. IC4H4600 Roulement Cuscinetto Lager 1.
Page 312 WATER PUMP EC4G5220 Impeller shaft 1. Install: 9Impeller shaft 1 NOTE: 9Take care so that the oil seal lip is not dam- aged or the spring does not slip off its position. 9When installing the impeller shaft, apply the lithium soap base grease on the oil seal lip and impeller shaft.
Page 313 POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA IC4G5220 Axe de turbine Flügelradwelle Albero del girante 1. Monter: 1. Einbauen: 1. Installare: 9 Albero del girante 1 9 Axe de turbine 1 9 Flügelradwelle 1 N.B.: ANMERKUNG: NOTA: 9 Prendre garde à ne pas endommager 9 Fare attenzione che il labbro del 9 Darauf achten, daß...
Page 314 CDI MAGNETO EC4L0000 CDI MAGNETO 8 Nm (0.8 m•kg, 5.8 ft•lb) 33 Nm (3.3 m•kg, 24 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) 1 CDI magneto removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CDI MAGNETO REMOVAL Preparation for Seat and fuel tank Refer to “SEAT, FUEL TANK AND...
Page 315 MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI MAGNETO CDI 1 Dépose de la magnéto CDI Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA MAGNETO CDI Préparation pour la dépose Selle et réservoir à essence Se reporter à la section “SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX”.
Page 316 CDI MAGNETO EC4L3000 REMOVAL POINTS EC4L3102 Rotor 1. Remove: 9Nut (rotor) 1 9Plain washer 2 Use the rotor holding tool 3. Rotor holding tool: YU-1235/90890-01235 2. Remove: 9Rotor 1 Use the flywheel puller 2. Flywheel puller: YM-1189/90890-01189 NOTE: When installing the flywheel puller, turn it coun- terclockwise.
Page 317 MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI IC4L3000 PUNTI DI RIMOZIONE POINTS DE DEPOSE AUSBAUPUNKTE IC4L3102 Rotore Rotor Rotor 1. Togliere: 1. Déposer: 1. Ausbauen: 9 Dado (rotore) 1 9 Ecrou (rotor) 1 9 Mutter (Rotor) 1 9 Rosetta 2 9 Rondelle ordinaire 2 9 Beilegescheibe 2 Usare l’utensile reggi-rotore 3.
Page 318 CDI MAGNETO 2. Install: 9Woodruff key 1 9Rotor 2 NOTE: 9Clean the tapered portions of the crankshaft and rotor. 9When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b. 9When installing the rotor, align the keyway c of the rotor with the woodruff key.
Page 319 MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI 2. Monter: 2. Einbauen: 2. Installare: 9 Clavette de demi-lune 1 9 Linguetta Woodruff 1 9 Einlegekeil 1 9 Rotor 2 9 Rotor 2 9 Rotore 2 N.B.: ANMERKUNG: NOTA: 9 Nettoyer la paritie conique de l’extré- 9 Pulire le parti coniche dell’albero a 9 Den Kegeligen Teil des Kurbelwel- mité...
Page 320 CDI MAGNETO 7. Connect: 9CDI magneto lead 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 8. Install: 9Gasket [crankcase cover (left)] 9Crankcase cover (left) 1 9Screw [crankcase cover (left)] 2 5 Nm (0.5 m•kg, 3.6 ft•lb) NOTE: Tighten the screws in stage, using a crisscross pattern.
Page 321 MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI 7. Connecter: 7. Anschließen: 7. Collegare: 9 Fil de magnéto CDI 1 9 Conduttore del magnete CDI 1 9 Kabel des CDI-Magnetzünders Se reporter à la section “SCHE- Consultare la sezione “DIA- MA DE CHEMINEMENT DES Siehe Abschnitt „KABEL-...
Page 322 ENGINE REMOVAL EC4M0000 26 Nm (2.6 m•kg, 19 ft•lb) 34 Nm (3.4 m•kg, 24 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 85 Nm (8.5 m•kg, 61 ft•lb) 60 Nm (6.0 m•kg, 43 ft•lb) Extent of removal Order Part name...
Page 323 DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE DEPOSE DU MOTEUR Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU MOTEUR Préparation pour la dépose Maintenir la machine en plaçant un Bien soutenir la la machine afin qu’elle ne risque support approprié...
Page 324 ENGINE REMOVAL 26 Nm (2.6 m•kg, 19 ft•lb) 34 Nm (3.4 m•kg, 24 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 85 Nm (8.5 m•kg, 61 ft•lb) 60 Nm (6.0 m•kg, 43 ft•lb) 1 Engine removal Extent of removal: Extent of removal...
Page 325 DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE 1 Dépose du moteur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques Couvercle de chaîne ü Ecrou (pignon d’entraînement) ý Rondelle-frein Se reporter à “POINTS DE DEPOSE”. þ...
Page 326 ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: 9Nut (drive sprocket) 1 9Lock washer 2 NOTE: 9Straighten the lock washer tab. 9Loosen the nut while applying the rear brake. 2. Remove: 9Drive sprocket 1 9Drive chain 2 NOTE: Remove the drive sprocket together with the dri- ve chain.
Page 327 DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE IC4M3000 PUNTI DI RIMOZIONE POINTS DE DEPOSE AUSBAUPUNKTE IC4F3100 Rocchetto conduttore Pignon d’entraînement Antriebskettenrad 1. Togliere: 1. Déposer: 1. Ausbauen: 9 Dado (rocchetto conduttore) 1 9 Ecrou (pignon d’entraînement) 1 9 Mutter (Antriebskettenrad) 1 9 Rosetta di sicurezza 2 9 Rondelle-frein 2 9 Sicherungsscheibe 2...
Page 328 ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION EC4M5171 Engine installation 1. Install: 9Engine 1 Install the engine from right side. 9Pivot shaft 2 85 Nm (8.5 m•kg, 61 ft•lb) 9Engine mounting bolt (lower) 3 69 Nm (6.9 m•kg, 50 ft•lb) 9Engine mounting bolt (front) 4 69 Nm (6.9 m•kg, 50 ft•lb) 9Engine bracket 5 9Bolt (engine bracket) 6...
Page 329 DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE IC4M5000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E MONTAGE INSTALLAZIONE Einbau des Motors 1. Einbauen: IC4M5171 Montage du moteur Installazione del motore 9 Motor 1 1. Monter: 1. Installare: Den Motor vonder rechten 9 Moteur 1 9 Motore 1 Seite einbauen.
Page 330 ENGINE REMOVAL 2. Install: 9Lock washer 1 9Nut (drive sprocket) 2 60 Nm (6.0 m•kg, 43 ft•lb) NOTE: Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4. Install: 9Chain cover 1 9Screw (chain cover) 2 5 Nm (0.5 m•kg, 3.6 ft•lb) 4-61...
Page 331 DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE 2. Monter: 2. Einbauen: 2. Installare: 9 Rondelle-frein 1 9 Rosetta di sicurezza 1 9 Sicherungsscheibe 1 9 Ecrou (pignon d’entraînement) 9 Mutter (Antriebskettenrad) 2 9 Dado (rocchetto conduttore) 2 60 Nm (6,0 m•kg, 43 ft•lb) 60 Nm (6,0 m•kg, 43 ft•lb) 60 Nm (6,0 m•kg, 43 ft•lb) ANMERKUNG:...
Page 332 CRANKCASE AND CRANKSHAFT EC4N0000 30 Nm (3.0 m•kg, 22 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 1 Crankcase separation 2 Crankshaft removal Extent of removal: 3 Crankshaft bearing removal Extent of removal Order Part name...
Page 333 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI CARTER ET VILEBREQUIN 1 Séparation du carter 2 Dépose du vilebrequin Etendue de dépose: 3 Dépose du roulement de vilebrequin Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU CARTER ET DU VILEBREQUIN Préparation pour la dépose...
Page 334 CRANKCASE AND CRANKSHAFT EC4N3000 REMOVAL POINTS EC4N3100 Segment 1. Remove: 9Bolt (segment) 1 9Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt. EC4N3211 Crankcase 1. Remove: 9Crankcase (right) 1 Use the crankcase separating tool 2 and crankcase separating bolt 3.
Page 335 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC4N3100 Segment Segment Segmento 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Boulon (segment) 1 9 Schraube (Segment) 1 9 Bullone (segmento) 1 9 Segment 2 9 Segment 2 9 Segmento 2...
Page 336 CRANKCASE AND CRANKSHAFT EC4N3301 Crankshaft 1. Remove: 9Crankshaft 1 Use the crankcase separating tool 2 and crankcase separating bolt 3. Crankcase separating tool: YU-1135-A/90890-01135 Crankcase separating bolt: YM-1305/90890-01305 Do not use a hammer to drive out the crankshaft. EC4N3401 Crankshaft bearing 1.
Page 337 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N3301 Vilebrequin Kurbelwelle Albero a gomiti 1. Déposer: 1. Togliere: 1. Ausbauen: 9 Albero a gomiti 1 9 Vilebrequin 1 9 Kurbelwelle 1 Utiliser le séparateur de carter Usare l’utensile per separare il Kurbelgehäuse-Trenn- 2 et le boulon de séparateur de carter 2 e il dado per separare...
Page 338 CRANKCASE AND CRANKSHAFT 2. Inspect: 9Bearings 1 Rotate inner race with a finger. Rough spot/Seizure Replace. 3. Inspect: 9Oil seal 1 Damage Replace. EC4N4202 Crankshaft 1. Measure: 9Runout limit a 9Small end free play limit b 9Connecting rod big end side clearance c 9Crank width d Out of specification Replace.
Page 339 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI 2. Examiner: 2. Prüfen: 2. Ispezionare: 9 Roulements 1 9 Cuscinetti 1 9 Lager 1 Faire tourner la bague intérieure inneren Laufring Ruotare l’anello interno con un avec le doigt. einem Finger drehen.
Page 340 CRANKCASE AND CRANKSHAFT EC4N5102 Oil seal 1. Install: 9Oil seal (left) 1 9Oil seal (right) 2 NOTE: 9Apply the lithium soap base grease on the oil seal lip. 9Install the oil seal with its manufacture’s marks or numbers facing outward. EC4N5272 Crankshaft 1.
Page 341 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N5102 Bague d’étanchéité Öldichtung Paraolio 1. Monter: 1. Einbauen: 1. Installare: 9 Paraolio (sinistro) 1 9 Bague d’étanchéité (gauche) 1 9 Öldichtung (Links) 1 9 Paraolio (destro) 2 9 Öldichtung (Rechts) 2 9 Bague d’étanchéité...
Page 342 Unsmooth operation Repair. 3. Apply: 9Sealant On the crankcase (right) 1 ® Quick gasket ACC-QUICK-GS-KT Yamaha bond No. 1215: 90890-85505 NOTE: Clean the contacting surface of crankcase (left and right) before applying the sealant. 4. Install: 9Dowel pin 1 9O-ring 2 9Crankcase (right) 3 To crankcase (left) 4.
Page 343 ® Quick Gasket ® Quick Gasket ® ACC-QUICK-GS-KT ACC-QUICK-GS-KT ACC-QUICK-GS-KT Yamaha Bond N°1215: Yamaha Bond No. 1215: Yamaha Bond Nr. 1215: 90890-85505 90890-85505 90890-85505 N.B.: NOTA: ANMERKUNG: Nettoyer la surface de contact des Pulire la superficie di contatto del carter...
Page 344 CRANKCASE AND CRANKSHAFT 6. Install: 9Holder 1 9Bolt (holder) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) 7. Install: 9Segment 1 9Bolt (segment) 2 30 Nm (3.0 m•kg, 22 ft•lb) NOTE: 9When installing the segment onto the shift cam 3, align the punch mark a with the dowel pin 9Turn the segment clockwise until it stops and tighten the bolt.
Page 345 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI 6. Monter: 6. Einbauen: 6. Installare: 9 Support 1 9 Supporto 1 9 Halter 1 9 Boulon (support) 2 9 Schraube (Halter) 2 9 Bullone (supporto) 2 10 Nm (1,0 m•kg, 7,2 ft•lb) 10 Nm (1,0 m•kg, 7,2 ft•lb) 10 Nm (1,0 m•kg, 7,2 ft•lb) 7.
Page 346 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Shift cam and shift fork removal 2 Main axle and drive axle removal Extent of removal: Extent of removal Order Part name Q’ty Remarks...
Page 347 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE 1 Dépose du barillet et de la fourchette Etendue de dépose: 2 Dépose de l’axe principal et de’axe moteur Etendue de dépose Ordre Nom de pièce...
Page 348 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS EC4H3200 Transmission 1. Remove: 9Main axle 1 9Drive axle 2 NOTE: 9Tap lightly on the transmission drive axle with a soft hammer to remove. 9Remove assembly carefully. Note the position of each part. Pay particular attention to the lo- cation and direction of shift forks.
Page 349 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO IC4H3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC4H3200 Boîte à vitesses Getribe Trasmissione 1. Déposer: 1. Togliere: 1. Ausbauen: 9 Axe principal 1 9 Asse principale 1 9 Hauptwelle 1...
Page 350 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4801 Shift fork, shift cam and segment 1. Inspect: 9Shift fork 1 Wear/Damage/Scratches Replace. 2. Inspect: 9Shift cam 1 9Segment 2 9Guide bar 3 Bend/Wear/Damage Replace. 3. Check: 9Shift fork movement On its guide bar. Unsmooth operation Replace shift fork and/or guide bar.
Page 351 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO IC4H4801 Fourchette, barillet de sélecteur et Schaltgabel, Schaltnocke und Segment Forcella del cambio, camma del cam- bio e segmento segment 1.
Page 352 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: 92nd wheel gear (28T) 1 96th wheel gear (24T) 2 94th wheel gear (27T) 3 93rd wheel gear (26T) 4 95th wheel gear (26T) 5 91st wheel gear (30T) 6 To drive axle 7. NOTE: 9Apply the molybdenum disulfide oil on the 1st, 2nd, 3rd and 4th wheel gears inner circumfer-...
Page 353 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO 2. Monter: 2. Einbauen: 2. Installare: 9 Roue de 2è (28D) 1 9 Ingranaggio a ruota 2 (28T) 1 Zahnrad für 2. Gang (28Z) 1 9 Roue de 6è...
Page 354 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H5331 Shift cam and shift fork 1. Install: 9Shift fork 1 (L) 1 9 Shift fork 2 2 9 Shift fork 3 (R) 3 NOTE: 9 Mesh the shift fork #1 (L) with the 6th wheel gear 4 and #3 (R) with the 5th wheel gear 6 on the drive axle.
Page 355 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO IC4H5331 Barillet de sélecteur et fourchette Schaltnocke und Schaltgabel Camma del cambio e forcella del cambio 1. Monter: 1. Einbauen: 1.
Page 356 CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 23 Nm (2.3 m•kg, 17 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 105 Nm (10.5 m•kg, 75 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb)
Page 357 ROUE AVANT ET ROUE ARRIEREF VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE ROUE AVANT 1 Dépose de la roue avant 2 Dépose du roulement de roue 3 Dépose du disque de frein Etendue de dépose: Etendue de dépose Ordre...
Page 358 CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL 14 Nm (1.4 m•kg, 10 ft•lb) 125 Nm (12.5 m•kg, 90 ft•lb) 42 Nm (4.2 m•kg, 30 ft•lb) 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal: Extent of removal Order Part name...
Page 359 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE ROUE ARRIERE 1 Dépose de roue arrière 2 Dépose du roulement de roue 3 Dépose du disque de frein Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 360 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: 9Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: 9Bearing 1 NOTE: Remove the bearing using a general bearing puller 2.
Page 361 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE IC593000 PUNTI DI RIMOZIONE POINTS DE DEPOSE AUSBAUPUNKTE Roue arrière Hinterrad IC523101 Ruota posteriore 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Roue 1 9 Rad 1 9 Ruota 1 N.B.: ANMERKUNG:...
Page 362 CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: 9Wheel 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 363 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE IC514200 Axe de roue Radachse Asse della ruota 1. Mesurer: 1. Messen: 1. Misurare: 9 Les flexions de l’axe de roue 9 Radachsenbiegung 9 Curvature dell’asse della ruota Hors-spécification Changer.
Page 364 CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION EC595101 Front wheel 1. Install: 9Bearing (left) 1 9Spacer 2 9Bearing (right) 3 9Oil seal 4 NOTE: 9 Apply the lithium soap base grease on the bearing and oil seal lip when installing. 9 Use a socket that matches the outside diam- eter of the race of the bearing.
Page 365 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE IC595000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E Vorderrad MONTAGE INSTALLAZIONE 1. Einbauen: Roue avant IC595101 9 Lager (Links) 1 1. Monter: Ruota anteriore 9 Distanzhülse 2 9 Roulement (gauche) 1 1.
Page 366 CHAS FRONT WHEEL AND REAR WHEEL 5. Install: 9Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. 6. Install: 9Nut (wheel axle) 1 105 Nm (10.5 m•kg, 75 ft•lb) 7. Tighten: 9Bolt (axle holder) 1 23 Nm (2.3 m•kg, 17 ft•lb) NOTE: Before tightening the bolt, fit the wheel axle to...
Page 367 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 5. Monter: 5. Einbauen: 5. Installare: 9 Axe de roue 1 9 Asse della ruota 1 9 Radachse 1 N.B.: NOTA: ANMERKUNG: Appliquer de la graisse à base de savon Das Lithiumfett auf Radachse auftra- Applicare sull’asse della ruota il grasso au lithium sur l’axe de roue.
Page 368 CHAS FRONT WHEEL AND REAR WHEEL 9. Install: 9Hose cover 1 9Plain washer 2 9Bolt [hose cover (M8)] 3 16 Nm (1.6 m•kg, 11 ft•lb) 9Bolt [hose cover (M6)] 4 7 Nm (0.7 m•kg, 5.1 ft•lb) EC5251A0 Rear wheel 1. Install: 9Bearing (right) 1 9Circlip 2 9Spacer 3...
Page 369 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 9. Monter: 9. Einbauen: 9. Installare: 9 Couvercle de tuyau 1 9 Copertura del tubo flessibile 1 9 Schlauchdeckel 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 9 Boulon 9 Schraube...
Page 370 CHAS FRONT WHEEL AND REAR WHEEL 3. Install: 9Driven sprocket 1 9Bolt (driven sprocket) 2 9Plain washer (driven sprocket) 3 9Nut (driven sprocket) 4 42 Nm (4.2 m•kg, 30 ft•lb) NOTE: Tighten the nuts in stage, using a crisscross pat- tern.
Page 371 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 3. Monter: 3. Einbauen: 3. Installare: 9 Pignon mené 1 9 Rocchetto condotto 1 9 Abtriebskettenrad 1 9 Boulon (pignon mené) 2 9 Schraube 9 Bullone (rocchetto condotto) 2 (Abtriebskettenrad) 9 Rondelle 9 Rosetta (rocchetto condotto) 3...
Page 372 CHAS FRONT WHEEL AND REAR WHEEL 8. Install: 9Chain puller (right) 1 9Plain washer 2 9Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point. 9. Adjust: 9Drive chain slack a Drive chain slack : 40~50 mm (1.6~2.0 in) Refer to “DRIVE CHAIN SLACK ADJUSTMENT”...
Page 373 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 8. Monter: 8. Einbauen: 8. Installare: 9 Tendeur de chaîne (droit) 1 9 Estrattore per catena (destro) 1 9 Kettenspanner (Rechts) 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 9 Ecrou (axe de roue) 3...
Page 374 CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 9 Nm (0.9 m•kg, 6.5 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb)
Page 375 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE FREIN AVANT ET FREIN ARRIERE FREIN AVANT 1 Dépose du tuyau de frein 2 Dépose de l’étrier 3 Dépose du maître-cylindre Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 376 CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE 7 Nm (0.7 m•kg, 5.1 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 1 Caliper removal...
Page 377 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE FREIN ARRIERE 1 Dépose de l’étrier 2 Dépose du tuyau de frein 3 Dépose du maître-cylindre Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 378 CHAS FRONT BRAKE AND REAR BRAKE EC5A8200 CALIPER DISASSEMBLY 3 Nm (0.3 m•kg, 2.2 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) A Front B Rear 1 Front caliper disassembly...
Page 379 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE DEMONTAGE DE L’ETRIER A Avant B Arrière 1 Démontage de l’étrier avant 2 Démontage de l’étrier arrière Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 380 CHAS FRONT BRAKE AND REAR BRAKE EC5A8300 MASTER CYLINDER DISASSEMBLY 2 Nm (0.2 m•kg, 1.4 ft•lb) A Front B Rear 1 Front master cylinder disassembly 2 Rear master cylinder disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks MASTER CYLINDER DISASSEMBLY Master cylinder cap...
Page 381 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE DEMONTAGE DU MAITRE-CYLINDRE A Avant B Arrière 1 Démontage du maître-cylindre avant 2 Démontage du maître-cylindre arrière Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 382 CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 REMOVAL POINTS EC5A3100 Brake fluid 1. Remove: [Front] 9Master cylinder cap 1 [Rear] 9Reservoir tank cap 1 9Protector NOTE: Do not remove the diaphragm. A Front B Rear 2. Connect the transparent hose 1 to the bleed screw 2 and place a suitable contain- er under its end.
Page 383 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE IC5A3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE Liquide de frein Bremsflüssigkeit IC5A3100 1. Déposer: 1. Ausbauen: Liquido per freni [Arrière] [Vorne] 1. Togliere: 9 Coupelle du maître-cylindre 1 9 Hauptbremszylinderkappe 1 [Anteriormente] [Avant]...
Page 384 CHAS FRONT BRAKE AND REAR BRAKE EC533402 Piston seal kit 1. Remove: 9Dust seal 1 9Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. Never attempt to pry out piston seals and dust seals.
Page 385 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE IC533402 Kit de joint de piston Kolbendichtungseinsatz Kit delle guarnizioni di tenuta del 1. Déposer: 1. Ausbauen: pistone 9 Joint antipoussière 1 9 Staubdichtung 1 1. Togliere: 9 Parapolvere 1 9 Joint de piston 2 9 Kolbendichtung 2...
Page 386 CHAS FRONT BRAKE AND REAR BRAKE EC534214 Caliper 1. Inspect: 9Caliper cylinder inner surface a Wear/Score marks Replace caliper as- sembly. A Front B Rear 2. Inspect: 9Caliper piston 1 Wear/Score marks Replace caliper piston assembly. Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled.
Page 387 FREAIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE IC534214 Etrier Bremssattel Pinza 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Surface 9 Inneren Oberfläche des Haupt- interne maître- 9 Superficie interna del cilindro cylindre a bremszylinders a della pinza a U s u r e / r a y u r e s...
Page 388 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9Piston seal 1 9Dust seal 2 Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. A Front B Rear 3.
Page 389 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Einbauen: 2. Installare: 9 Joint de piston 1 9 Guarnizione di tenuta del pisto- 9 Kolbendichtung 1 9 Joint antipoussière 2 9 Staubdichtung 2 ne 1 9 Parapolvere 2 Toujours utiliser des joints de piston...
Page 390 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9Copper washer 1 9Union bolt 2 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers. Install the brake hose so that its pipe por- tion a a directs as show and lightly touches the projection b b on the caliper.
Page 391 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Einbauen: 2. Installare: 9 Rondelle en cuivre 1 9 Rondella in rame 1 9 Kupferscheibe 1 9 Boulon d’union 2 9 Unionschraube 2 9 Bullone di unione 2 30 Nm (3,0 m•kg, 22 ft•lb) 30 Nm (3,0 m•kg, 22 ft•lb)
Page 392 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9Disc cover 1 9Bolt (disc cover) 2 7 Nm (0.7 m•kg, 5.1 ft•lb) 3. Install: 9Copper washer 1 9Brake hose 2 9Union bolt 3 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers. Install the brake hose to the caliper with the paint a a on the pipe facing the caliper and with the pipe contacting the caliper...
Page 393 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Einbauen: 2. Installare: 9 Couvercle de disque 1 9 Copridisco 1 9 Scheibendeckel 1 9 Boulon (couvercle de disque) 2 9 Schraube (Scheibendeckel) 2 9 Bullone (copridisco) 2 7 Nm (0,7 m•kg, 5,1 ft•lb) 7 Nm (0,7 m•kg, 5,1 ft•lb)
Page 394 CHAS FRONT BRAKE AND REAR BRAKE EC5A5220 Master cylinder kit 1. Clean: 9Master cylinder 9Master cylinder kit Clean them with brake fluid. 2. Install: 9Master cylinder cup (primary) 1 9Master cylinder cup (secondary) 2 To master cylinder piston 3. NOTE: Apply the brake fluid on the master cylinder cup.
Page 395 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE IC5A5220 Kit de maître-cylindre Hauptbremszylindersatz Kit del cilindro principale 1. Nettoyer: 1. Reinigen: 1. Pulire: 9 Maître-cylndre 9 Hauptbremszylinder 9 Cilindro principale 9 Kit de maître-cylindre 9 Hauptbremszylindereinsatz 9 Kit del cilindro principale Les nettoyer avec le liquide de...
Page 396 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: [Front] 9Master cylinder kit 1 9Plain washer 2 9Circlip 3 9Master cylinder boot 4 To master cylinder 5. [Rear] 9Master cylinder kit 1 9Push rod 2 9Circlip 3 9Master cylinder boot 4 To master cylinder 5.
Page 397 FREIN AVNAT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 4. Monter: 4. Einbauen: 4. Installare: [Avant] [Vorne] [Anteriormente] 9 Kit de maître-cylindre 1 9 Hauptbremszylindersatz 1 9 Kit del cilindro principale 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 9 Circlip 3...
Page 398 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9Brake lever 1 9Bolt (brake lever) 2 6 Nm (0.6 m•kg, 4.3 ft•lb) 9Nut (brake lever) 3 6 Nm (0.6 m•kg, 4.3 ft•lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston.
Page 399 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Einbauen: 2. Installare: 9 Levier de frein 1 9 Leva di comando del freno 1 9 Bremshebel 1 9 Boulon (levier de frein) 2 9 Schraube (Bremshebel) 2 9 Bullone (leva di comando del freno) 2...
Page 400 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: 9Pin 1 9Plain washer 2 9Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3. EC5A5911 Front brake hose 1. Install: 9Brake hose 1 10 Nm (1.0 m•kg, 7.2 ft•lb) To brake hose holder 2.
Page 401 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE AND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 4. Monter: 4. Einbauen: 4. Installare: 9 Goupille 1 9 Spina 1 9 Stift 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 9 Goupille fendue 3 9 Splint 3 9 Coppiglia 3 N.B.:...
Page 402 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: 9Copper washer 1 9Brake hose 2 9Union bolt 3 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers. Install the brake hose so that its pipe por- tion a a directs as show and lightly touches the projection b b on the master cylinder.
Page 403 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 4. Monter: 4. Einbauen: 4. Installare: 9 Roudelle en cuivre 1 9 Rondella in rame 1 9 Kupferscheibe 1 9 Tuyau de frein 2 9 Bremsschlauch 2 9 Tubo flessibile del freno 2 9 Boulon d’union 3 9 Unionschraube 3...
Page 404 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9Brake hose holder 1 9Screw (brake hose holder) 2 4 Nm (0.4 m•kg, 2.9 ft•lb) After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist.
Page 405 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Einbauen: 2. Installare: 9 Support de tuyau de frein 1 9 Supporto del tubo flessibile del 9 Bremsschlauchhalter 1 9 Vis (support de tuyau de frein) 2 9 Schraube (Bremsschlauchhal- freno 1 ter) 2...
Page 406 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: 9Brake system Refer to “BRAKE SYSTEM AIR BLEED- ING” section in the CHAPTER 3. 3. Inspect: 9Brake fluid level Fluid at lower level Fill up. Refer to “BRAKE FLUID LEVEL INSPEC- TION”...
Page 407 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Purger de l’air: 2. Entlüften: 2. Spurgo dell’aria: 9 Système de freinage 9 Impianto frenante 9 Bremsanlage Se reporter à la section “PRISE Siehe Abschnitt „ENTLÜFTEN Consultare la sezione “SPUR- D’AIR DU SYSTEME DE BREMSANLAGE“...
Page 408 CHAS FRONT FORK EC550000 4 Nm (0.4 m•kg, 2.9 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Front fork removal Extent of removal: Extent of removal...
Page 409 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE FOURCHE AVANT 1 Dépose de la fourche avant Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA FOURCHE AVANT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas approprié...
Page 410 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY 29 Nm (2.9 m•kg, 21 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) 1 Oil seal removal 2 Damper rod removal Extent of removal: Extent of removal Order Part name...
Page 411 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE DEMONTAGE DE LA FOURCHE AVANT 1 Dépose de la bague d’étanchéité 2 Dépose de la tige d’amortisseur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEMONTAGE DE LA FOURCHE AVANT Boulon capuchon Se reporter à...
Page 412 CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. To prevent an accidental explosion of air, the following instructions should be ob- served: 9 The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to...
Page 413 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC556000 REMARQUES HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO CONCERNANT LA ANMERKUNG: NOTA: MANIPULATION Die Vorderradgabel erfordert beson- La forcella anteriore richiede grande at- dere Aufmerksamkeit. Daher wird N.B.: tenzione. Si raccomanda pertanto di ef- empfohlen, Wartungsarbeiten an der fettuare la manutenzione della forcella La fourche avant nécessite une soigneu- Vorderradgebel...
Page 414 CHAS FRONT FORK EC553201 Inner tube 1. Remove: 9Dust seal 1 9Stopper ring 2 Using slotted-head screwdriver. Take care not to scratch the inner tube. 2. Remove: 9Inner tube 1 Oil seal removal steps: 9 Push in slowly a the inner tube just be- fore it bottoms out and then pull it back quickly b.
Page 415 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC553201 Tube interne Innere Rohr Tubo interno 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Joint antipoussière 1 9 Staubdichtung 1 9 Parapolvere 1 9 Bague d’arrêt 2 9 Anschlagring 2 9 Anello di fermo 2 En utilisant un tournevis à...
Page 416 CHAS FRONT FORK EC554200 Base valve 1. Inspect: 9Valve assembly 1 Wear/Damage Replace. 9O-ring 2 Damage Replace. EC554400 Fork spring 1. Measure: 9Fork spring free length a Out of specification Replace. Fork spring free length: Standard <Limit> 460 mm 455 mm (18.1 in) (17.9 in) EC554502...
Page 417 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC554200 Soupare de base Hauptventil Valvola di base 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Gruppo valvola 1 9 Ensemble clapet 1 9 Ventileinheit 1 Usure/endommagement Abnutzung/Beschädigung Usura/Danni Sostituirlo. 9 Anello di tenuta 2 Changer.
Page 418 CHAS FRONT FORK EC554700 Cap bolt 1. Inspect: 9Cap bolt 1 9O-ring 2 9Air bleed screw 3 Wear/Damage Replace. EC555000 ASSEMBLY AND INSTALLATION EC5551A1 Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: 9Damper rod 1 To inner tube 2.
Page 419 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC554700 Boulon capuchon Hutschraube Vite mordente 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Boulon capuchon 1 9 Hutschraube 1 9 Vite mordente 1 9 Joint torique 2 9 O-Ring 2 9 Anello di tenuta 2 9 Vis de purge d’air 3 9 Entlüftungschraube 3 9 Vite di spurgo dell’aria 3...
Page 420 CHAS FRONT FORK 5. Install: 9Spring guide 1 9Locknut 2 To damper rod 3. NOTE: 9Install the spring guide with its cut a facing up- ward. 9With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6.
Page 421 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 5. Monter: 5. Einbauen: 5. Installare: 9 Guide de ressort 1 9 Guida della molla 1 9 Federführung 1 9 Contre-ecrou 2 9 Sicherungsmutter 2 9 Controdado 2 Au tige d’amortisseur 3. Zum Dämpfungsstange 3. Sulla barra dello smorzatore 3.
Page 422 CHAS FRONT FORK 9. Install: 9Slide metal 1 9 Plain washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-01442/90890-01442 10. Install: 9Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2.
Page 423 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 9. Monter: 9. Einbauen: 9. Installare: 9 Bague antifriction 1 9 Metallo di scorrimento 1 9 Gleitmetall 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 Vers la fente de tube externe. Schlitz äußeren Sulla fessura del tubo esterno.
Page 424 CHAS FRONT FORK 13. Check: 9Inner tube smooth movement Tightness/Binding/Rough spots Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: 9Front fork oil Until outer tube top surface with recom- mended fork oil 1. Recommended oil: Suspension oil “01”...
Page 425 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 13. Contrôler: 13. Kontrollieren: 13. Controllare: 9 Mouvement régulier du tube in- 9 Facilità di movimento del tubo 9 Glatte Bewegung des inneres terne Rohres Festsitz/Klemmung interno Raideur/coincement/point dure /Unregel-mäßige Bewegung Difficoltà/Inceppamento Répéter les étapes du 2 au 12. Die Schritte 2 bis 12 wieder- /Ruvidità...
Page 426 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 427 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 19. Attendre dix minutes jusqu’à ce 19. Vor dem Einstellen des empfoh- 19. Attendere dieci minuti finché le que les bulles d’air aient été élimi- lenen Ölpegels, etwa zehn bolle d’aria sono state tolte dalla nées de la fourche avant et que Minuten warten,...
Page 428 CHAS FRONT FORK 21. Measure: 9Distance a Out of specification Turn into the locknut. a a : Distance 20 mm (0.79 in) or more Between damper rod 1 1 top and locknut 2 2 top. 22. Loosen: 9Rebound damping adjuster 1 NOTE: 9Loosen the rebound damping adjuster finger tight.
Page 429 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 21. Mesurer: 21. Messen: 21. Misurare: 9 Distance a 9 Distanza a 9 Maß a Hors spécification Rentrer le Abweichung von Spezifikation Fuori specifica Avvitare il con- contre-écrou. Sicherungsmutter trodado. hineindrehen. Distanza a a : a a : Distance Maß...
Page 430 CHAS FRONT FORK 26. Tighten: 9Cap bolt (locknut) 1 29 Nm (2.9 m•kg, 21 ft•lb) NOTE: 9While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4. 9Hold the locknut 5 and tighten the cap bolt with specified torque.
Page 431 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 26. Serrer: 26. Festziehen: 26. Serrare: 9 Boulon capuchon 1 9 Vite mordente (controdado) 1 9 Hutschraube 1 ft•lb) 29 Nm (2,9 m•kg, 21 ft•lb) 29 Nm (2,9 m•kg, 21 ft•lb) 29 Nm (2,9 m•kg, 21 ANMERKUNG: N.B.: NOTA:...
Page 432 CHAS FRONT FORK 4. Tighten: 9Pinch bolt (handle crown) 1 23 Nm (2.3 m•kg, 17 ft•lb) 9Pinch bolt (under bracket) 2 20 Nm (2.0 m•kg, 14 ft•lb) Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.
Page 433 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 4. Serrer: 4. Festziehen: 4. Serrare: 9 Boulon de bridage (couronne de 9 Bullone di serraggio (corona del 9 Klemmschraube (Lenkerkrone) guidon) 1 manubrio) 1 23 Nm (2,3 m•kg, 17 ft•lb) 23 Nm (2,3 m•kg, 17 ft•lb) 23 Nm (2,3 m•kg, 17 ft•lb) 9 Boulon de bridage (étrier infé- 9 Bullone di serraggio (staffa in-...
Page 434 CHAS HANDLEBAR EC5B0000 1 Nm (0.1 m•kg, 0.7 ft•lb) 9 Nm (0.9 m•kg, 6.5 ft•lb) 28 Nm (2.8 m•kg, 20 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 2 Nm (0.2 m•kg, 1.4 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Handlebar removal Extent of removal: Extent of removal Order...
Page 435 GUIDON LENKSTANGE CHAS MANUBRIO GUIDON 1 Dépose du guidon Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU GUIDON Préparation Plaque d’immatriculation Enlever seulement la partie de fixation. pour la dépose Câble d’embrayage Déconnecter du côté levier. Support de levièr d’embrayage Bouton d’arrêt du moteur “ENGINE STOP”...
Page 436 CHAS HANDLEBAR EC5B8000 THROTTLE DISASSEMBLY 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Throttle disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks THROTTLE DISASSEMBLY Grip cap (lower) Grip cap (upper) Grip assembly Grip (right) Refer to “REMOVAL POINTS”. Tube guide 5-41...
Page 437 GUIDON LENKSTANGE CHAS MANUBRIO DEMONTAGE DE L’ACCELERATEUR 1 Démontage de l’accélérateur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEMONTAGE DE L’ACCELERA- TEUR Capuchon de poigée (inférieur) Capuchon de poigée (supérieur) Ensemble de la poignée Poignée (droite) Se reporter à...
Page 438 CHAS HANDLEBAR EC5B3000 REMOVAL POINTS EC5B3100 Master cylinder 1. Remove: 9Master cylinder bracket 1 9Master cylinder 2 9Do not let the master cylinder hang on the brake hose. 9Keep the master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip 1.
Page 439 GUIDON LENKSTANGE CHAS MANUBRIO IC5B3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC5B3100 Maître-cylindre Hauptbremszylinder Cilindro principale 1. Déposer: 1. Ausbausen: 1. Togliere: 9 Etrier de maître-cylindre sur 1 9 Hauptbremszylinderhalterung 9 Staffa del cilindro principale 1 9 Maître-cylindre 2 9 Cilindro principale 2 9 Hauptbremszylinder 2 9 Ne pas laisser pendre le maître-cy-...
Page 440 CHAS HANDLEBAR 2. Install: 9Grip cap (upper) 1 9Grip cap (lower) 2 9Bolt (grip cap) 3 NOTE: Temporarily tighten the bolts (grip cap). EC5B5210 Handlebar 1. Install: 9Handlebar 1 9Handlebar holder 2 9Bolt (handlebar holder) 3 28 Nm (2.8 m•kg, 20 ft•lb) NOTE: 9The upper handlebar holder should be installed with the punched mark a forward.
Page 441 GUIDON LENKSTANGE CHAS MANUBRIO 2. Monter: 2. Einbauen: 2. Installare: 9 Capuchon de poignée (supé- 9 Calotta della manopola (supe- 9 Griffkappe (Oben) 1 rieur) 1 9 Griffkappe (Unten) 2 riore) 1 9 Capuchon de poignée (inférieur) 9 Schraube (Griffkappe) 3 9 Calotta della manopola (inferio- re) 2 ANMERKUNG:...
Page 442 CHAS HANDLEBAR 4. Install: 9Throttle cable 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throt- tle cable end and tube guide cable winding por- tion. 5. Install: 9Roller 1 9Collar 2 NOTE: 9Apply the lithium soap base grease on the roller sliding surface.
Page 443 GUIDON LENKSTANGE CHAS MANUBRIO 4. Monter: 4. Einbauen: 4. Installare: 9 Câble d’accélérateur 1 9 Cavo dell’acceleratore 1 9 Gasseil 1 Au guide de tube 2. An der Rohrführung 2. Sulla guida del tubo 2. ANMERKUNG: N.B.: NOTA: Appliquer de la graisse à base de savon Lithium-Fett am Gasseilende und Applicare sull’estremità...
Page 444 CHAS HANDLEBAR 10. Install: 9Bolt (grip cap) 1 4 Nm (0.4 m•kg, 2.9 ft•lb) 9Install the grip cap so that the gaps a a and b b between the bolt (grip cap) and brake lever 2 2 are equal. If you make a mistake in the grip cap installation position, the brake lever may contact the grip cap, resulting in poor brake performance.
Page 445 GUIDON LENKSTANGE CHAS MANUBRIO 10. Monter: 10. Einbauen: 10. Installare: 9 Boulon (capuchon de poignée) 9 Bullone (calotta della manopo- 9 Schraube (Griffkappe) 1 la) 1 4 Nm (0,4 m•kg, 2,9 ft•lb) 4 Nm (0,4 m•kg, 2,9 ft•lb) 4 Nm (0,4 m•kg, 2,9 ft•lb) 9 Die Griffkappe so einbauen, daß...
Page 446 CHAS HANDLEBAR 14. Clamp the clamp portion a of the number plate to the handlebar. 15. Insert the end of the fuel breather hose 1 into the hole of the number plate. 5-46...
Page 447 GUIDON LENKSTANGE CHAS MANUBRIO 14. Fixer la partie de fixation a de la 14. Bloccare la parte della brida a 14. Das Klemmteil Nummernschildes plaque d’immatriculation au gui- della targa sul manubrio. Lenkstange festklemmen. don. 15. Inserire l’estremità dello sfiato del carburante 1 nel foro della targa.
Page 448 CHAS STEERING EC560000 23 Nm (2.3 m•kg, 17 ft•lb) 145 Nm (14.5 m•kg, 105 ft•lb) TIGHTENING STEPS: 9 Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) 9 Loosen it one turn. 9 Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 1 Under bracket removal 2 Bearing removal Extent of removal:...
Page 449 DIRECTION LENKUNG CHAS STERZO DIRECTION ETAPES DE SERRAGE: 9 Serrer l’ecrou annulaire a environ. 38 Nm (3,8 m•kg, 27 ft•lb) 9 Le desserrer d’un tour. 9 Le resserrer a enviorn. 7 Nm (0,7 m•kg, 5,1 ft•lb) 1 Dépose de l’étrier inférieur 2 Dépose du roulement Etendue de dépose: Etendue de dépose...
Page 450 CHAS STEERING EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: 9 Ring nut 1 Use the ring nut wrench 2. Ring nut wrench: YU-33975/90890-01403 Support the steering shaft so that it may not fall down. EC563300 Bearing (lower) 1. Remove: 9Bearing (lower) 1 Use the floor chisel 2.
Page 451 DIRECTION LENKUNG CHAS STERZO IC563000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC563202 Ecrou annulaire Ringmutter Ghiera 1. Déposer: 1. Ausbauen: 1. Togilere: 9 Ecrou annulaire 1 9 Ringmutter 1 9 Ghiera 1 Den Ringmutterschlüssel 2 Utiliser la clé pour écrou annu- Usare la chiave per ghiera 2.
Page 452 CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a sol- vent. 2. Inspect: 9 Bearing 1 9 Ball race Pitting/Damage Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand.
Page 453 DIRECTION LENKUNG CHAS STERZO IC564101 Roulement et cage à billes Lager und Laufring Cuscinetto e pista 1. Nettoyer les roulements et les 1. Die Lager Laufringe 1. Lavare i cuscinetti e le piste con cages à billes dans du solvant. Lösungsmittel waschen.
Page 454 CHAS STEERING 4. Install: 9 Plain washer 1 9 Ring nut 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Tighten the ring nut using the ring nut wrench 3. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAP- TER 3. 5.
Page 455 DIRECTION LENKUNG CHAS STERZO 4. Monter: 4. Einbauen: 4. Installare: 9 Rondelle ordinaire 1 9 Rosetta 1 9 Beilegescheibe 1 9 Ecrou annulaire 2 9 Ringmutter 2 9 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•kg, 5,1 ft•lb) Serrer l’écrou annulaire 3 en Ringmutter...
Page 456 CHAS STEERING 9. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 10. Adjust: 9 Front fork top end a Front fork top end (standard) a a : 5 mm (0.20 in) 11.
Page 457 DIRECTION LENKUNG CHAS STERZO 9. Après avoir serré l’écrou, vérifier 9. Nach dem Festziehen der Mutter, 9. Dopo avere serrato il dado, con- si le mouvement de la direction est die Lenkung auf glatte Bewegung trollare che lo sterzo si muova sen- régulier.
Page 458 CHAS SWINGARM EC570000 53 Nm (5.3 m•kg, 38 ft•lb) 80 Nm (8.0 m•kg, 58 ft•lb) 7 Nm (0.7 m•kg, 51 ft•lb) 19 Nm (1.9 m•kg, 13 ft•lb) 85 Nm (8.5 m•kg, 61 ft•lb) 1 Swingarm removal Extent of removal: Extent of removal Order Part name Q’ty...
Page 459 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE BRAS OSCILLANT 1 Dépose du bras oscillant Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU BRAS OSCILLANT Préparation Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas pour la dépose approprié...
Page 460 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY 80 Nm (8.0 m•kg, 58 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) 80 Nm (8.0 m•kg, 58 ft•lb) 1 Swingarm disassembly 2 Connecting rod removal and disassembly Extent of removal: 3 Relay arm removal and disassembly Extent of removal Order Part name...
Page 461 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE DEMONTAGE DU BRAS OSCILLANT 1 Démontage du bras oscillant 2 Dépose et démontage de la bielle Etendue de dépose: 3 Dépose et démontage du bras de relais Etendue de dépose Ordre Nom de pièce Q’té...
Page 462 CHAS SWINGARM EC573000 REMOVAL POINTS EC573200 Bearing 1. Remove: 9Bearing 1 NOTE: Install the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes, collars, and covers in a solvent. EC574111 Swingarm 1. Inspect: 9Bearing 1 9Bush 2 Free play exists/Unsmooth revolution/Rust Replace bearing and bush as a set.
Page 463 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE IC573000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC573200 Cuscinetto Roulement Lager 1. Togliere: 1. Déposer: 1. Ausbauen: 9 Cuscinetto 1 9 Roulement 1 9 Lager 1 NOTA: N.B.: ANMERKUNG: Installare il cuscinetto premendone Monter le roulement en appuyant sur la Das Lager am äußeren Laufring ein- l’anello esterno.
Page 464 CHAS SWINGARM EC575000 ASSEMBLY AND INSTALLATION EC575202 Bearing and oil seal 1. Install: 9Bearing 1 9Oil seal 2 To swingarm. NOTE: 9Apply the molybdenum disulfide grease on the bearing when installing. 9Install the bearing by pressing it on the side hav- ing the manufacture's marks or numbers.
Page 465 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE IC575000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E MONTAGE INSTALLAZIONE IC575202 Lager und Öldichtung Roulement et bague d’étanchéité Cuscinetto e paraolio 1. Einbauen: 1. Monter: 1. Installare: 9 Lager 1 9 Roulement 1 9 Cuscinetto 1 9 Öldichtung 2 9 Bague d’étanchéité...
Page 466 CHAS SWINGARM EC5751B1 Swingarm 1. Install: 9 Bush 1 9 Thrust bearing 2 9 Oil seal 3 Collar 4 To swingarm 5. NOTE: Apply the molybdenum disulfide grease on the bushes, thrust bearings and oil seal lips. 2. Install: 9Collar 1 To relay arm 2.
Page 467 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE IC5751B1 Bras oscillant Hinterradschwinge Forcellone oscillante 1. Monter: 1. Einbauen: 1. Installare: 9 Bague 1 9 Buchse 1 9 Boccola 1 9 Roulement de butée 2 9 Drucklager 2 9 Cuscinetto reggispinta 2 9 Bague d’étanchéité 3 9 Öldichtung 3 9 Paraolio 3 9 Collerette 4...
Page 468 CHAS SWINGARM 5. Install: 9Relay arm 1 9Bolt (relay arm) 2 9Plain washer 3 9Nut (relay arm) 4 To swingarm. NOTE: 9Apply the molybdenum disulfide grease on the bolt. 9Do not tighten the nut yet. 6. Install: 9Swingarm 1 9Pivot shaft 2 85 Nm (8.5 m•kg, 61 ft•lb) NOTE: 9Apply the molybdenum disulfide grease on the...
Page 469 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE 5. Monter: 5. Einbauen: 5. Installare: 9 Bras de relais 1 9 Braccio di rinvio 1 9 Relaisarm 1 9 Boulon (bras de relais) 2 9 Schraube (Relaisarm) 2 9 Bullone (braccio di rinvio) 2 9 Rondelle ordinaire 3 9 Beilegescheibe 3 9 Rosetta 3...
Page 470 CHAS SWINGARM 10. Tighten: 9Nut (connecting rod) 1 80 Nm (8.0 m•kg, 58 ft•lb) 11. Tighten: 9Nut (relay arm) 1 80 Nm (8.0 m•kg, 58 ft•lb) 12. Install: 9Cap 1 NOTE: Install the cap with its mark a facing forward. 13.
Page 471 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE 10. Serrer: 10. Festziehen: 10. Serrare: 9 Ecrou (bielle) 1 9 Dado (leva di rinvio) 1 9 Mutter (Pleuelstange) 1 80 Nm (8,0 m•kg, 58 ft•lb) 80 Nm (8,0 m•kg, 58 ft•lb) 80 Nm (8,0 m•kg, 58 ft•lb) 11.
Page 472 CHAS REAR SHOCK ABSORBER EC580000 56 Nm (5.6 m•kg, 40 ft•lb) 53 Nm (5.3 m•kg, 38 ft•lb) 29 Nm (2.9 m•kg, 21 ft•lb) 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks...
Page 473 AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE AMORTISSEUR ARRIERE 1 Dépose de l’amortisseur arrière 2 Démontage de l’amortisseur arrière Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE L’AMORTISSEUR ARRIERE Bien soutenir la machine afin qu’elle ne risque pas Préparation Maintenir la machine en plaçant un support de se renverser.
Page 474 1. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. To dispose of a damaged or worn-out shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5-60...
Page 475 Anweisungen beachten. IC587000 REMARQUE CONCER- NOTE SULLO SMALTI- NANT LA MISEAU REBUT VERSCHROTTUNGSANLEI- MENTO (SOLTANTO CON- TUNG (NUR FÜR YAMAHA DE L’AMORTISSEUR CESSIONARI YAMAHA) Prima di smaltire l’ammortizzatore, as- FACHHÄNDLER) (TRAVAIL A EFFECTUER sicurarsi di estrarre l’azoto gassoso dal-...
Page 476 CHAS REAR SHOCK ABSORBER EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: 9Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: 9Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3.
Page 477 AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE IC583000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC583320 Roulement Lager Cuscinetto 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Bague d’arrêt (roulement supé- 9 Anschlagring (Oben Lager) 1 9 Anello di fermo (cuscinetto su- rieur) 1 periore) 1 ANMERKUNG:...
Page 478 CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585320 Bearing 1. Install: 9Upper Bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear- ing is press fitted.
Page 479 AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE IC585000 REMONTAGE ET MONTA- MONTAGE UND EINBAU MONTAGGIO E INSTAL- LAZIONE IC585320 Lager Roulement Cuscinetto 1. Einbauen: 1. Monter: 1. Installare: 9 Oben Lager 1 9 Roulement supérieur 1 9 Cuscinetto superiore 1 ANMERKUNG: N.B.: NOTA: Das Lager am äußeren Laufring paral-...
Page 480 CHAS REAR SHOCK ABSORBER 3. Adjust: 9Spring length (installed) a Spring length (installed) a a : Standard Extent of length adjustment 248 mm (9.76 in) 242~260 mm (9.53~10.24 in) *262 mm (10.31 in) *257~275 mm (10.12~10.83 in) *For EUROPE NOTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster.
Page 481 AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE 3. Régler: 3. Einstellen: 3. Regolare: 9 Longueur de ressort a 9 Lunghezza della molla (installa- 9 Länge der Feder a ta) a Länge der Feder (einge- Longueur de ressort baute)a: (monté)a: Lunghezza della molla (installata)a: Standard-.
Page 482 CHAS REAR SHOCK ABSORBER 3. Install: 9Rear shock absorber 4. Install: 9Bolt (rear shock absorber-frame) 1 9Nut (rear shock absorber-frame) 2 56 Nm (5.6 m•kg, 40 ft•lb) NOTE: Apply the molybdenum disulfide grease on the bolt. 5. Install: 9Plain washer 1 9Bolt (rear shock absorber-relay arm) 2 53 Nm (5.3 m•kg, 38 ft•lb) NOTE:...
Page 483 AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE 3. Monter: 3. Einbauen: 3. Installare: 9 Amortisseur arrière 9 Ammortizzatore posteriore Hinterrad-Stoßdämpfer 4. Monter: 4. Einbauen: 4. Installare: 9 Boulon (ammortisseur arrière— 9 Bullone (ammortizzatore poste- Schraube (Hinterrad-Stoß- cadre) 1 riore–telaio) 1 dämpfer—Rahmen) 1 9 Ecrou (amortisseur arrière—...
Page 484 ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 “ENGINE STOP” button COLOR CODE 2 Ignition coil B....Black 3 CDI unit O ....Orange 4 CDI magneto B/R ....Brack/Red 5 Spark plug B/W ....Black/White G/L ....Green/Blue G/W....Green/White...
Page 485 COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN ELEC COMPONENTI ELETTRICI E SCHEMA ELETTRICO IC600000 PARTIE ELETRIQUE ELEKTRISCHE PARTE ELETTRICA COMPOSANTS EINRICHTUNGEN IC610000 ELECTRIQUES ET COMPONENTI ELEKTRISCHE BAUTEILE SCHEMA DE CABLAGE ELETTRICI E SCHEMA UND SCHALTPLAN COMPOSANTS ELECTRIQUES ELEKTRISCHE BAUTEILE ELETTRICO 1 Bouton d’arrêt du moteur “ENGINE...
Page 486 ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM EC621002 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 487 ELEC SYSTEME D’ALLUMAGE SYSTEME D’ALLUMAGE ETAPES DE VERIFICATION Utiliser les étapes suivantes pour vérifier la possibilité d’attribution du mauvais fonctionnement du moteur à une panne du circuit d’allumage et pour vérifier la bougie d’allumage qui n’allume pas. Etincelle Essai de l’intervalle d’étincellement *Nettoyer ou remplacer d’allumage.
Page 488 ELEC ZÜNDANLAGE ZÜNDANLAGE PRÜFVORGÄNGE Durch folgende Schritte auf eine mögliche Störung des Motors durch einen Defekt im Zündsystem prü- fen und Ausfindigmachen einer aussetzenden Zündkerze. Zündfunke *Zündkerze reinigen oder Test der Zündfunkenstrecke erneuern. Kein Zündfunke Die Anschlüsse der gesamten Nicht in Ordnung Erneuern oder reparieren.
Page 489 ELEC SISTEMA DI ACCENSIONE IC620000 SISTEMA DI ACCENSIONE IC621002 OPERAZIONI DI ISPEZIONE Usare le operazioni che seguono per controllare la possibilità che il malfunzionamento del motore sia attribuibile a un guasto del sistema di accensione e per controllare la candela che non emette scintille. Scintilla Test della distanza tra gli elettrodi *Pulire o sostituire la candela.
Page 490 ELEC IGNITION SYSTEM EC622001 å SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (igni- tion checker 2 ) as shown. 9Spark plug cap 3 9Spark plug 4 A For USA and CDN B Except for USA and CDN ∫...
Page 491 SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE IC622001 ESSAI DE L’INTERVALLE TEST DER ZÜNDFUNKENSTRECKE TEST DELLA DISTANZA TRA D’ETINCELLEMENT 1. Den Zündkerzenstecker von der GLI ELETTRODI D’ALLUMAGE Zündkerze abtrennen. 1. Scollegare la calotta della candela 1. Déconnecter le capuchon de bou- 2.
Page 492 ELEC IGNITION SYSTEM EC626002 IGNITION COIL INSPECTION 1. Inspect: 9Primary coil resistance Out of specification Replace. Tester (+) lead Orange lead 1 Tester (–) lead Black lead 2 Primary coil Tester selector resistance position 0.14~0.20½ at ½ ´ 1 20°C (68°F) 2.
Page 493 SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE IC626002 VERIFICATION DE LA BOBINE INSPEKTION DER ZÜNDSPULE ISPEZIONE DELLA BOBINA DI D’ALLUMAGE 1. Prüfen: ACCENSIONE 9 Widerstand der Primärspule 1. Examiner: 1. Ispezionare: 9 Résistance de bobine primaire Abweichung von Spezifikation 9 Resistenza della bobina prima- Hors spécification Changer.
Page 494 ELEC IGNITION SYSTEM EC627011 CDI MAGNETO INSPECTION 1. Inspect: 9Pick-up coil resistance Out of specification Replace. Tester (+) lead White/ Red lead 1 Tester (–) lead White/ Blue lead 2 Pick–up coil Tester selector resistance position 248~372½ at ½ ´ 100 20°C (68°F) 2.
Page 495 SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE IC627011 VERIFICATION DE LA INSPEKTION DES ISPEZIONE DEL MAGNETE CDI MAGNETO CDI CDI-MAGNETZÜNDERS 1. Ispezionare: 1. Examiner: 1 Prüfen: 9 Resistenza della bobina esplora- 9 Résistance de bobine d’excita- 9 Widerstand der Aufnahmespu- trice tion Fuori specifica...
Page 496 SETTING EC700000 TUNING EC710000 ENGINE EC711001 Carburetor setting 9The role of fuel is to cool the engine, and in the case of a 2-stroke engine, to lubricate the engine addition power generation. Accordingly, if a mixture of air and fuel is too lean, abnormal combustion will occur, and engine seizure may result.
Page 497 REGLAGE EINSTELLUNG REGISTRAZIONE IC700000 MISE AU POINT TUNING MESSA A PUNTO MOTEUR MOTOR IC710000 Réglage du carburateur Vergasereinstellung MOTORE 9 Le rôle du carburant consiste à 9 Zusätzlich zu der Krafterzeugung IC711001 refroidir le moteur et dans le cas dient der Kraftstoff auch zur Kühlung Registrazione del carburatore d’un moteur à...
Page 498 SETTING That is: 9Higher temperature expands the air with its resultant reduced density. 9Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air. 9Lower atmospheric pressure (at a high altitude) reduces the density of the air.
Page 499 REGLAGE EINSTELLUNG REGISTRAZIONE Ainsi: Das heißt: Cioè: 9 Une température plus élevée dilate 9 Una temperatura più alta fa dilatare 9 Eine höhere Temperatur führt zu l’air et en réduit la densité. einer Ausdehnung der Luft und l’aria; ne risulta una densità ridotta. 9 Une humidité...
Page 500 SETTING EC714060 Effect of setting parts in relation to throttle valve opening Throttle valve opening Setting part Full-closed 1/4 3/4 Full-open Pilot air screw Pilot jet Diameter of straight portion Clip position Throttle valve Main jet 1 Throttle valve opening 2 Full-open 3 Full-closed EC715002...
Page 501 REGLAGE EINSTELLUNG REGISTRAZIONE IC714060 Ajustement de pièces à l’ouverture Wirkung der Einstellteile in Bezie- Effetto delle parti di registrazione in du papillon des gaz hung zur Öffnung der Drosselklappe relazione all’apertura della valvola regolatrice del flusso Ouverture du papillon des gaz Drosselklappenöffnung Voll- Voll-...
Page 502 SETTING EC716001 Pilot air screw adjustment The richness of air-fuel mixture with full closed to 1/4 throttle can be set by turning the pilot air screw 1. Turning in the pilot air screw will enrich the mix- ture at low speeds, and turning out it will lean out the mixture.
Page 503 REGLAGE EINSTELLUNG REGISTRAZIONE IC716001 Réglage de la vis de richesse Einstellung der Leerlauf-Luftregu- Regolazione della vite dell’aria pilota La richesse du mélange air-carburant lierschraube La ricchezza della miscela aria-carbu- avec le papillon des gaz fermé à 1/4 Der Kraftstoffgehalt des Luft/Kraftstoffge- rante con la valvola regolatrice del flus- peut être réglée en tournant la vis de misches bei vollständig geschlossener...
Page 504 SETTING EC718010 Jet needle groove position adjustment Should the engine be hard to run smoothly at intermediate speeds, the jet needle 1 must be adjusted. If the mixture is too rich or too lean at intermediate speed operation, irregular engine operation and poor acceleration will result.
Page 505 REGLAGE EINSTELLUNG REGISTRAZIONE IC718010 Einstellung der Position der Düsen- Regolazione della posizione della sca- Réglage de la position de la rainure nadelnut nalatura sull’ago a getto de l’aiguille de gicleur Falls der Motor bei mittleren Drehzahlen Se dovesse essere difficile far girare il Si le moteur a des difficultés à...
Page 506 SETTING EC719071 Jet needle adjustment (For USA, CDN, ZA, AUS and NZ) On the carburetors used in the YZ125, the main nozzle is a non disassembly type, so it can not replaced. Therefore, carburetor setting requires the change of the jet needle. 6BGK9-74 6BGK9-75 1.
Page 507 REGLAGE Réglage de l’aiguille de gicleur (Pour USA, CDN, ZA, AUS et NZ) Sur les carburateurs utilisés sur la YZ125, le gicleur principal n’est pas démontable de sorte qu’il ne peut être remplacé. C’est pourquoi le réglage du carburateur nécessite le remplacement 6BGK9-74 de l’aiguille.
Page 508 EINSTELLUNG Düsennadel-Einstellung (Für USA, CDN, ZA, AUS und NZ) An den im Modell YZ125 verwendeten Verga- sern kann die Hauptdüse nicht ausgebaut und somit nicht ausgewechselt werden. Die Verga- sereinstellung erfordert deshalb das Auswech- 6BGK9-74 seln der Düsennadel. 6BGK9-75 6BGK9-76 1.
Page 509 REGISTRAZIONE IC719071 Regolazione dell’ago a getto (Per USA, CDN, ZA, AUS e NZ) Sui carburatori usati nella YZ125 l’ugello principa- le è di tipo non smontabile e quindi non può essere sostituito. Pertanto, la registrazione del carburatore richiede il cambiamento dell’ago a getto. 6BGK9-74 6BGK9-75 1.
Page 510 SETTING EC719071 Jet needle adjustment (For EUROPE) On the carburetors used in the YZ125, the main nozzle is a non disassembly type, so it can not replaced. Therefore, carburetor setting requires the change of the jet needle. 6BHY1-74 6BHY1-75 1. The jet needle setting parts, having the same 6BHY1-76 taper angle, are available in different straight portion diameters and in different taper start-...
Page 511 REGLAGE Réglage de l’aiguille de gicleur (Pour EUROPE) Sur les carburateurs utilisés sur la YZ125, le gicleur principal n’est pas démontable de sorte qu’il ne peut être remplacé. C’est pourquoi le réglage du carburateur nécessite le remplacement 6BHY1-74 de l’aiguille. 6BHY1-75 6BHY1-76 1.
Page 512 EINSTELLUNG Düsennadel-Einstellung (Für EUROPA) An den im Modell YZ125 verwendeten Verga- sern kann die Hauptdüse nicht ausgebaut und somit nicht ausgewechselt werden. Die Verga- sereinstellung erfordert deshalb das Auswech- 6BHY1-74 seln der Düsennadel. 6BHY1-75 6BHY1-76 1. Die Düsennadel-Einstellteile mit dem glei- chen Konuswinkel sind in Ausführungen mit unterschiedlichen Durchmessern des gera- den Teils und mit unterschiedlichen Konus-...
Page 513 REGISTRAZIONE IC719071 Regolazione dell’ago a getto (Per EUROPA) Sui carburatori usati nella YZ125 l’ugello principa- le è di tipo non smontabile e quindi non può essere sostituito. Pertanto, la registrazione del carburatore richiede il cambiamento dell’ago a getto. 6BHY1-74 6BHY1-75 1.
Page 514 SETTING EC71B040 Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet needle. On the relationship between the fuel flow and the throttle opening, the fuel flow relates to the straight portion of the jet needle at full closed~1/8 throttle, to the 1st...
Page 515 REGLAGE EINSTELLUNG REGISTRAZIONE IC71B040 Relation avec l’ouverture du papillon Zusammenhang mit der Drosselöff- Rapporto con l’apertura della valvo- L’arrivée du carburant dans le système nung la a farfalla principal du carburateur est contrôlée Der Kraftstofffluß durch das Hauptsy- flusso del carburante attraverso il siste- par le gicleur principal, puis est encore stem des Vergasers wird von der ma principale del carburatore è...
Page 516 SETTING EC71Q000 Carburetor setting parts Part name Size Part number Main jet Lean #420 137-14143-84 #430 137-14143-86 #440 137-14143-88 *(STD) #450 137-14143-90 (STD) #460 137-14143-92 #470 137-14143-94 #480 137-14143-96 Rich #490 137-14143-98 Pilot jet 2 2 Lean 4KM-14142-20 #22.5 4KM-14142-22 (STD) 4KM-14142-25 #27.5...
Page 517 REGLAGE EINSTELLUNG REGISTRAZIONE IC71Q000 Pièces de réglage du carburateur Vergaser-Einstellteile Parti di regolazione del carburatore Numéro Dimen- Numero Teilebezeichnung Größe Teilenummer Nom de pièce Taille Particolare de pièce sioni categorico Haupt- Mager #420 137-14143-84 Gicleur Pauvre #420 137-14143-84 düse Getto Povera No.
Page 518 SETTING EC71C020 Road condition and examples of carburetor setting Conditions General condition Sandy condition Under 10°C 15~25°C Over 30°C Under 10°C 15~25°C Over 30°C (50°F) (59~77°F) (86°F) (50°F) (59~77°F) (86°F) Parts (Winter) (Spring, Autumn) (Summer) (Winter) (Spring, Autumn) (Summer) #470 #460 #450 #490...
Page 519 SETTING Symptom Setting Checking 0~1/4 throttle Use jet needle having a smaller Number of turns-back *Hard breathing diameter. Correct properly Speed down Overflow from carburetor 0~1/4 throttle Use jet needle having a larger Poor acceleration diameter. White smoke Unstable at low speeds Lower jet needle clip position.
Page 520 REGLAGE Conditions de la route et exemples de réglages de carburateur Conditions Générales Sablonneux Moins 15 à 25°C Plus de 30°C Moins de 15 à 25°C Plus de 30°C de 10°C (50°F) (86°F) 10°C (50°F) (86°F) (59 à 77°F) (59 à 77°F) Pièce (Hiver) (Eté)
Page 521 REGLAGE Symptômes Réglages Contrôler 0~1/4 de papillon Utiliser une aiguille de gicleur avec un Nombre de tours de dévissage diamètre inférieur. Corriger correctement *Attaque difficile Perte de vitesse Fuite en provenance du carburateur Utiliser une aiguille de gicleur avec un 0~1/4 de papillon Mauvaise accélération diamètre supérieur.
Page 522 EINSTELLUNG Straßenbedingungen und Beispiele für die Vergasereinstellung Normal Sandig Bedingungen Unter 10°C 15~25°C Über 30°C Unter 10°C 15~25°C Über 30°C (50°F) (59~77°F) (86°F) (50°F) (59~77°F) (86°F) Teile (Winter) (Sommer) (Winter) (Sommer) (Frühling, Herbst) (Frühling, Herbst) #470 #460 #450 #490 #480 #470 Hauptdüse *#460...
Page 523 EINSTELLUNG Symptom Einstellung Prüfung 0~1/4 Gas Eine Düsennadel mit kleinerem Anzahl der Ausdrehungen * Hartes Beatmen Durchmesser verwenden. Richtig korrigieren Überlauf am Niedrige Drehzahl Vergaser 0~1/4 Gas Eine düsennadel mit größerem Schlechte Durchmesser verwenden. Beschleunigung Weißer Rauch Unstabil bei niedriger Düsennadel-Klemmenposition Drehzahl absenken (1 Nut nigdriger)
Page 524 REGISTRAZIONE IC71C012 Condizioni stradali ed esempi di registrazione del carburatore Condizioni Condizioni generiche Condizioni di sabbia Meno di 10°C 15~25°C Più di 30°C Meno di 10°C 15~25°C Più di 30°C (50°F) (59~77°F) (86°F) (50°F) (59~77°F) (86°F) Parti (inverno) (primavera, autunno) (estate) (inverno) (primavera, autunno)
Page 525 REGISTRAZIONE Sintomo Registrazione Controllo Valvola a farfalla a 0 ~ 1/4 Usare un ago a getto che abbia un Numero di giri in senso contrario *Respirazione difficoltosa diametro più piccolo. Correggere adeguatamente Velocità bassa Traboccamento dal carburatore Valvola a farfalla a 0 ~ 1/4 Usare un ago a getto che abbia un Accelerazione scarsa diametro più...
Page 526 SETTING EC71M001 Change of the heat range of spark plugs Judging from the discoloration of spark plugs, if they are found improper, it can be corrected by the following two methods; changing carburetor settings and changing the heat range of spark plug.
Page 527 REGLAGE EINSTELLUNG REGISTRAZIONE IC71M001 Changement de plage de chaleur des Änderung des Wärmebereichs der Cambiamento della gamma termica bougies Zündkerzen delle candele En fonction de la décoloration des bou- Falls anhand der Verfärbung der Giudicando dallo scolorimento delle gies, si elle n’est pas normale, elle peut Zündkerzen eine falsche Einstellung candele, se si rileva che sono inadegua- être corrigée par les deux méthodes qui...
Page 528 SETTING EC720000 CHASSIS EC71P002 Selection of the secondary reduction ratio (Sprocket) Secondary Number of driven sprocket teeth reduction = —————————————— Number of drive sprocket teeth ratio Standard secondary 48/13 (3.692) reduction ratio <Requirement for selection of secondary gear reduction ratio> 9It is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for...
Page 529 REGLAGE EINSTELLUNG REGISTRAZIONE IC720000 PARTIE CYCLE FAHRGESTELL TELAIO Sélection du taux de réduction secon- Auswahl des Sekundär- IC71P002 daire (Pignons) Untersetzungsverhältnisses Selezione del rapporto di riduzione (Kettenrad) secondario (Rocchetto) Nombre de dents du pignon mené Anzahl der Zähne am Numero di denti Taux de réduction angetriebenen Kettenrad del rocchetto condotto...
Page 530 SETTING EC72N000 Drive and driven sprockets setting parts Part name Size Part number Drive sprocket 9383A-12017 (STD) 9383A-13031 9383A-14054 Driven sprocket 2 2 5ET-25447-00 (STD) 5ET-25448-00 5ET-25449-00 5ET-25450-00 5ET-25451-00 5ET-25452-00 EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit.
Page 531 REGLAGE EINSTELLUNG REGISTRAZIONE IC72N000 Pièces de réglage des pignons méné et Antriebs- und Abtriebskettenrad- Parti di regolazione del rocchetto menant Einstellteile conduttore e condotto Numéro Dimen- Numero Teilebezeichnung Größe Teilenummer Nom de pièce Taille Particolare de pièce sioni categorico Antriebskettenrad 9383A-12017 Pignon de sortie 9383A-12017...
Page 532 SETTING EC722011 Front fork setting The front fork setting should be made depending on the rider’s feeling of an actual run and the cir- cuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics 9Change the fork oil level.
Page 533 REGLAGE EINSTELLUNG REGISTRAZIONE IC722011 Réglages de la fourche avant Einstellung der Vorderradgabel Registrazione della forcella anteriore Régler la fourche avant en fonction de Die Einstellung der Vorderradgabel La registrazione della forcella anteriore la sensation lors de la conduite ainsi soll entsperechend dem Gefühl des dovrebbe essere effettuata in base alla sen- que des conditions du terrain.
Page 534 SETTING EC727021 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. Do not install three or more adjustment washers for each front fork. Always adjust each front fork to the same setting.
Page 535 REGLAGE EINSTELLUNG REGISTRAZIONE IC727021 Réglage de tension initiale du ressort Einstellung der Federvorspannung Regolazione del precarico della molla Le tension initiale du ressort a été ajus- Die Federvorspannung wird einge- Il precarico della molla viene regolato tée en montant la rondelle de réglage 1 stellt, indem die Einstellscheibe 1 installando la rondella di regolazione entre le ressort de fourche 2 et la tige...
Page 536 SETTING 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of con- tact with the road surface or in a vibrating handlebar. To set a stiff spring: 9Change the rebound damping.
Page 537 REGLAGE EINSTELLUNG REGISTRAZIONE 2. Ressort dur 2. Verwendung einer harten Feder 2. Uso di una molla rigida En principe, un ressort dur offre Normaleweise bewirkt eine harte Generalmente una molla rigida dà une sensation de conduite dure. La Feder ein hartes Fahrgefühl. Die una sensazione di guida rigida.
Page 538 SETTING EC72P010 Front fork setting parts 9 Adjustment washer 1 TYPE (thickness) PART NUMBER T=2.3 mm (0.09 in) 4SS-23364-L0 9Front fork spring 2 [Equal pitch spring ] I.D. SPRING SPRING TYPE MARK RATE PART NUMBER (slits) 0.380 4SS-23141-10 SOFT 0.390 4SS-23141-20 I-II 0.400...
Page 539 REGLAGE EINSTELLUNG REGISTRAZIONE IC72P010 Pièces de réglage de la fourche avant Vorderradgabel-Einstellteile Parti di regolazione della forcella 9 Rondelle de réglage 1 9 Einstellscheibe 1 anteriore 9 Rondella di regolazione 1 TYP (Dicke) TEILENUMMER TYPE (epaisseur) NUMERO DE PIECE TIPO (spessore) NUMERO CATEGORICO T=2,3 mm (0,09 in) 4SS-23364-L0 T=2,3 mm (0,09 in)
Page 540 SETTING EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the follow- ing two factors: 1. Setting of spring preload 9Change the set length of the spring.
Page 541 REGLAGE EINSTELLUNG REGISTRAZIONE IC72B000 Réglage de la suspension arrière Einstellung der Hinterradfederung Registrazione della sospensione Effectuer le réglage de la suspension Die Einstellung der Hinterradfederung posteriore arrière en fonction de la sensation lors soll entsprechend dem Gefühl des La registrazione della sospensione de la conduite ainsi que des conditions Fahrers nach einer Testfahrt und den posteriore dovrebbe essere effettuata in...
Page 542 SETTING NOTE: 9If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re-evaluation. 9If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make re-adjustment.
Page 543 REGLAGE EINSTELLUNG REGISTRAZIONE N.B.: NOTA: ANMERKUNG: 9 Le ressort peut s’allonger au fur et à 9 Se il veicolo è nuovo e dopo il rodag- 9 Wenn eine neue Maschine eingefah- mesure de la période de rodage. Il est ren worden ist, kann es sein, daß die gio, la stessa lunghezza registrata donc important...
Page 544 SETTING When using a rear cushion other than cur- rently installed, use the one whose overall a a does not exceed the standard as length it may result in faulty performance. Never use one whose overall length is greater than standard. Length a a of standard shock: 485.5 mm (19.11 in) å...
Page 545 REGLAGE EINSTELLUNG REGISTRAZIONE Lors du remplacement du ressort de Bei Verwendung eines anderen hin- Quando si usa un ammortizzatore la suspension arrière, veiller à mon- teren Stoßdämpfers posteriore diverso da quello attual- ter un ressort dont la longueur totale momentan eingebauten verwenden mente installato, usarne uno la cui a a n’excède pas la longueur standard lunghezza totale a a non superi quella...
Page 546 SETTING EC72Q011 Rear shock absorber setting parts 9Rear shock spring 1 [Equal pitch spring ] I.D. SPRING SPRING SPRING TYPE COLOR FREE RATE PART NUMBER /POINT LENGTH SOFT 5DH-22212-70 Brown/1 5DH-22212-10 Green/1 5DH-22212-20 Red/1 5DH-22212-30 Black/1 STIFF 5DH-22212-40 Blue/1 5DH-22212-50 Yellow/1 5DH-22212-60 Pink/1...
Page 547 REGLAGE EINSTELLUNG REGISTRAZIONE IC72Q011 Pièces de réglage de l’amortisseur Hinterradstoßdämpfer-Einstellteile Parti di regolazione dell’ammortizza- 9 Hinterradstoßdämpfer-Schrauben arrière tore posteriore 9 Ressort d’amortisseur arrière 1 feder 1 9 Molla dell’ammortizzatore posteriore [Ressort à pas égal] [Feder mit gleichmäßiger Gewinde- steigung] [Molla di passo unguale] CONSTANTE NUMERO DE REPERE Longueur MARCATURA Lunghezza...
Page 548 SETTING EC72H010 Suspension setting 9Front fork NOTE: 9If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. 9Before any change, set the rear shock absorber sunken length to the standard figure 90~100 mm (3.5~3.9 in).
Page 549 SETTING 9Rear shock absorber NOTE: 9If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. 9Adjust the rebound damping in 2-click increments or decrements. 9Adjust the low compression damping in 1-click increments or decrements.
Page 550 REGLAGE Réglage de la suspension 9 Fourche avant N.B.: 9 Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectur un nouveau réglage en se référant aux procédés repris dans ce tableau. 9 Avant d’effectuer toute modification, régler la longueur enfoncée de l’amortisseur arrière à la valeur stan- dard de 90~100 mm (3,5~3,9 in).
Page 551 REGLAGE 9 Amortisseur arrière N.B.: 9 Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, ettectur un nouveau réglage en se référant aux procédés repris dans ce tableau. 9 Ajuster la force de rebond par incréments et décréments de 2 déclics. 9 Ajuster la force d’amortissement de compression basse par incréments ou décréments de 1 déclic.
Page 552 EINSTELLUNG Federungseinstellung 9 Vorderradgabel ANMERKUNG: 9Wenn eines der folgenden Symptome mit der Standardeinstellung als Basis auftritt, nehmen Sie eine Nachstellung unter Beachtung der in der Tabelle gezeigten Einstellschritte vor. 9Vor jeder Änderung stellen Sie die eingetauchte Länge des Hinterrad-Stoßdämpfers auf den Stan- dardwert von 90~100 mm (3,5~3,9 in) ein.
Page 553 EINSTELLUNG 9 Hinterradstoßdämpfer ANMERKUNG: 9Wenn eines der folgenden Symptome mit der Standardeinstellung als Basis auftritt, nehmen Sie eine Nachstellung unter Beachtung der in der Tabelle gezeigten Einstellschritte vor. 9Einstellung der Ausfederdämpfung jeweils in Schritten von 2 Vorwärts- oder Rückwärts-Klickstellun- gen. 9Einstellung der niedrige Einfederdämpfung jeweils in Schritten von 1 Vorwärts- oder Rückwärts-Klick- stellung.
Page 554 REGISTRAZIONE IC72H010 Registrazione della sospensione 9 Forcella anteriore NOTA: 9 Se si verifica uno qualsiasi dei seguenti sintomi con la posizione normale come base, effettuare la ri-regi- strazione facendo riferimento alla procedura di registrazione fornita nella stessa tabella. 9 Prima di qualsiasi modifica, registrare la lunghezza abbassata dell’ammortizzatore posteriore sulla cifra normale di 90~100 mm (3,5~3,9 in).
Page 555 REGISTRAZIONE • Ammortizzatore posteriore NOTA: 9 Se si verifica uno qualsiasi dei seguenti sintomi con la posizione normale come base, effettuare la ri-regi- strazione facendo riferimento alla procedura di registrazione fornita nella stessa tabella. 9 Regolare lo smorzamento dell’estensione in incrementi o decrementi di 2 scatti. 9 Regolare lo smorzamento a bassa compressione in incrementi o decrementi di 1 scatto.
Page 556 MEMO...
Page 558 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2000.6 – 2.4 × 1 PRINTED ON RECYCLED PAPER (E • F • G • I)

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