Page 1 OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER-UND WARTUNGS-HANDBUCH MANUALE DI SEVIZIO DEL PROPRIETARIO YZ1 25 ( P ) /LC 5NY-28199-30...
Page 2 EC010010 YZ125(P)/LC OWNER’S SERVICE MANUAL ©2001 by Yamaha Motor Co., Ltd. 1st Edition, May 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...
Page 3 MANUALE DI SERVIZIO DEL WARTUNGSHANDBUCH DU PROPRIETAIRE PROPRIETARIO ©2001 der Yamaha Motor Co., Ltd. ©2001 Yamaha Motor Co.,Ltd. © 2001 by Yamaha Motor Co., Ltd. 1. Ausgabe, Mai 2001 1ère Edition, Mai 2001 1a Edizione, Mei 2001 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, con-...
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 Handbuches oder Ihrer Maschine auftauchen sollten, wen- Poids des machines sans carbu- Pesi dei veicoli senza carburante rant den Sie sich bitte an Ihren Yamaha I pesi minimi per i veicoli per moto- Les poids minimum admis pour les Fachhändler. cross sono:...
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., Bearings...
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 DESCRIZIONE ...........1-1 BESCHREIBUNG ........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 MOTORE MOTOR SELLE, RESERVOIR A ESSENCE SITZ, KRAFTSTOFFTANK UND SELLA, SERBATOIO DEL ET COUVERCLES LATERAUX....4-1 CARBURANTE E COPERTURE SEITENDECKEL.........4-1 LATERALI ..........4-1 TUYAU D’ECHAPPEMENT ET AUSPUFFROHR UND SILENCIEUX ..........4-3 SCHALLDÄMPFER ........4-3 TUBO DI SCARICO E 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 PARTE ELETTRICA ELEKTRISCHE ELECTRIQUE EINRICHTUNGEN COMPOSANTS ELECTRIQUES ELEKTRISCHE BAUTEILE UND COMPONENTI ELETTRICI E SCHEMA 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 CAPITOLO 7 KAPITEL 7 MISE AU POINT...
Page 26 DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 NOTE: DESCRIPTION 1 Clutch lever The machine you have purchased may differ 2 ”ENGINE STOP” button slightly from those shown in the following. 3 Front brake lever Designs 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. Silencer end Air filter intake slit Crankcase 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 ZIONE E LO SMONTAGGIO AUSBAU UND DER DEMONTAGE 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: Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off.
Page 37 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 EC140002 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” MOTORE” STOP“ 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 LEVA DI COMANDO DEL FRENO HANDBREMSHEBEL 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 EC160051 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 IC160051 ESSENCE ET HUILE DE KRAFTSTOFF UND 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 MISE EN MARCHE ET STARTEN UND EINFAH- AVVIAMENTO E RODAGE RODAGGIO Avant la mise en marche, effectuez Prima di avviare il veicolo, eseguire i les vérifications indiquées dans la controlli della lista di controllo prima Vor dem Anfahren der Maschine, liste de contrôle avant utilisation.
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 PROCEDURE DI RODAGGIO EINFAHRVORGÄNGE 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 After 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. When 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 Dopo il rodaggio o prima di ciascu- 9 Nach dem Einfahren und vor course, il faut vérifier toutes les na gara, si deve controllare tutto il jedem Rennen müssen Sie gemäß...
Page 60 TORQUE-CHECK POINTS INFO EC1A0013 TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering shaft to Steering shaft to frame handlebar Steering shaft to handle crown Handle crown to handlebar...
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 Du support du moteur au moteur Du support du moteur au cadre Direction...
Page 62 ANZUGSMOMENTE-PRÜFPUNKTE INFO ANZUGSMOMENTE-PRÜFPUNKTE Rahmenkonstruktion Rahmen und Hintere Rahmen Kombinierter Sitz und Tank Kraftstofftank am Rahmen Motoraufhängung Rahmen am Motor Motoraufhängung am Motor Motoraufhängung am Rahmen Lenkung Lenkerschaft Lenkerschaft am Rahmen an Lenkstange Lenkerschaft an Lenkerkrone Lenkerkrone an Lenkstange Radaufhängung Vorne Lenkerschaft an Vorderradgabel an Lenkerkrone Vorderradgabel...
Page 63 PUNTI DI CONTROLLO DELLA COPPIA INFO IC1A0013 PUNTI DI CONTROLLO DELLA COPPIA Costruzione del telaio Telaio-telaio posteriore Sella e serbatoio uniti Serbatoio del carburante-telaio Supporto del motore Telaio-motore Staffa motore-motore Staffa motore-telaio 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 NETTOYAGE ET REINIGEN UND 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 IMMAGAZZINAMENTO LAGERUNG 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- dere misure preventive per evitare un...
Page 68 SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: YZ125LC (EUROPE) YZ125P1 (USA) YZ125(P) (CDN, AUS, NZ, ZA) Model code number: 5NY1 (USA, CDN, ZA) 5NY2 (EUROPE) 5NY4 (AUS, NZ) Dimensions: USA, ZA AUS, NZ EUROPE ← ← Overall length 2,134 mm 2,130 mm (84.0 in)
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 49/13 (3.769) Transmission type Constant mesh, 5-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 Ignition timing (B.T.D.C.) 0.52 mm (0.020 in) … Advancer type Electrical CDI: … Magneto-model (stator)/Manufacturer 4SS-01/YAMAHA … 720~1,080 Ω at 20°C (68°F) Source coil 1 resistance (color) (Green/White-Black/Red) … 44~66 Ω 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) YZ125P1 (USA) YZ125(P) (CDN, AUS, NZ, ZA) Numéro de code de modèle: 5NY1 (USA, CDN, ZA) 5NY2 (EUROPE) 5NY4 (AUS, NZ) Dimensions: USA, ZA AUS, NZ EUROPE ← ← Longueur hors-tout 2.134 mm 2.130 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 49/13 (3,769) 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 … 248~372 Ω à 20°C (68°F) Résistance de bobinage d’excitation (couleur) (blanc/bleu-blanc/rouge) … Bloc CDI-Modèle/Fabricant 5NY-00/YAMAHA (Excepté pour EUROPE) 5NY-10/YAMAHA (Pour EUROPE) Bobine d’allumage: … Modèle/Fabricant 4SS-00/YAMAHA … Etincellement minimale 6 mm (0,24 in) 0,14~0,20 Ω à 20°C (68°F) …...
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) YZ125P1 (USA) YZ125(P) (CDN, AUS, NZ, ZA) Modell-Code-Nummer: 5NY1 (USA, CDN, ZA) 5NY2 (EUROPA) 5NY4 (AUS, NZ) Abmessungen: USA, ZA AUS, NZ EUROPA ← ← Gesamtlänge 2.134 mm 2.130 mm (84,0 in) (83,9 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 49/13 (3,769) Getriebebauart Syncrongetriebe, 5-Gang Bedienungssystem Linker Fuß Untersetzungsverhältnis: 1. Gang 27/12 (2,250) 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=4,02 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 HINWEIS 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 (Schwarz-Grün/Blau) … 248~372 Ω bei 20°C (68°F) Widerstand der Aufnahmespule (Farbe) (Weiß/Blau-Weiß/Rot) … CDI Einheit-Modell/Hersteller 5NY-00/YAMAHA (Außer für EUROPA) 5NY-10/YAMAHA (Für EUROPA) Zündspule: … Modell/Hersteller 4SS-00/YAMAHA … Mindestzündfunkenstrecke 6 mm (0,24 in) … 0,14~0,20 Ω bei 20°C (68°F) Widerstand der Primärwicklung …...
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) YZ125P1 (USA) YZ125(P) (CDN, AUS, NZ, ZA) Numero di codice del modello: 5NY1 (USA, CDN, ZA) 5NY2 (EUROPA) 5NY4 (AUS, NZ) Dimensioni: USA, ZA AUS, NZ EUROPA CDN, ←...
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 49/13 (3,769)
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 Messa in fase dell’accensione (B.T.D.C.) 0,52 mm (0,020 in) … Tipo di anticipatore Elettrico CDI: … Modello (statore)/Costruttore del magnete 4SS-01/YAMAHA … 720~1.080 Ω à 20°C (68°F) Resistenza 1 della bobina di origine (colore) (Verde/Bianco-Nero/Rosso) 44~66 Ω à 20°C (68°F) …...
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 CABLE ROUTING DIAGRAM A Pass the throttle cable and F Clamp the CDI magneto lead 1 Brake hose 2 Cable guide “ENGINE STOP” button lead on the upper part of 3 “ENGINE STOP” button lead into the cable guide.
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 Guida per cavi 2 Kabelführung 1 Tuyau de frein 3 Conduttore del pulsante “ARRESTO 3 Leitungskabel des Motorstoppknopfes 2 Guide de câble...
Page 118 SPEC CABLE ROUTING DIAGRAM L Pass the radiater breather hose and CDI magneto lead between the frame and radiator. M Align the top of the brake hose neck with the brake hose holder bottom. N Pass the brake hose in front of the axle boss, then fit it into the hose groove so that the brake hose does not...
Page 119 SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI L Den ¬ Faire passer le tuyau de reniflard du radia- ¬ Far passare lo sfiato del radiatore e il Kühler-Belüftungsschlauch das Leitungskabel des CDI-Magnetzün- conduttore del magnete CDI fra il telaio teur et le fil de magnéto CDI entre le châs- ders zwischen dem Rahmen und dem e il radiatore.
Page 120 SPEC CABLE ROUTING DIAGRAM A Pass the cluch cable into H Fit the CDI unit band over 1 Cable guide 2 Radiator breather hose the cable guide. the CDI unit bracket till it B Pass the clutch cable over 3 Ignition coil stops.
Page 121 SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Guide de câble 1 Kabelführung 1 Guida per cavi 2 Tuyau de reniflard de radiateur 2 Kühler-Belüftungsschlauch 2 Sfiato del radiatore 3 Bobine d’allumage 3 Zündspule 3 Bobina di accensione 4 Fil de magnéto CDI 4 Leitungskabel des CDI-Magnetzünders 4 Conduttore del magnete CDI...
Page 122 SPEC CABLE ROUTING DIAGRAM A Pass the reservoir hose between the brake 1 Hose guide 2 Master cylinder hose and swingarm bracket. B Install the brake hose to the caliper with the 3 Brake hose holder 4 Brake hose paint on the pipe facing the caliper and with the pipe contacting the caliper projection.
Page 123 SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Guide de tuyau 1 Schlauchführung 1 Guida per tubo flessible 2 Maître-cylindre 2 Hauptbremszylinder 2 Cilindro principale 3 Support de tuyau de frein 3 Bremsschlauchhalter 3 Support del tubo flessibile del freno 4 Tuyau de frein 4 Bremsschlauch 4 Tubo flessibile del freno...
Page 124 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 125 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 126 If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. After...
Page 127 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 128 INSP MEMO...
Page 129 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 130 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 131 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 132 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 133 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 134 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 135 Se si hanno dubbi sugli interval- li da seguire per la manutenzione e la lubrificazione del veicolo, consultare il concessionario Yamaha. In base...
Page 136 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 137 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 138 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 139 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 140 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 141 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 142 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 143 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 144 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: Coolant drain bolt 1 3. Remove: Radiator cap Drain the coolant completely. 4.
Page 145 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 146 INSP RADIATOR CAP INSPECTION Do not mix more than one type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be handled with special care.
Page 147 VERIFICATION DU BOUCHON DU RADIATEUR INSP INSPEKTION DES KÜHLERDECKELS ISPEZIONE DEL TAPPO DEL RADIATORE 9 Ne pas mélanger plusieurs solutions 9 Non miscelare più di un tipo di anti- 9 Niemals Äthylenglykol-Frost- antigel au glycol d’éthyle contenant gelo a base di glicole etilenico conte- schutzmittel Korrosions- des produits anticorrosion pour...
Page 148 RADIATOR CAP OPENING PRESSURE INSPECTION/ INSP COOLING SYSTEM INSPECTION EC356002 RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: Radiator 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 149 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 150 INSP CLUTCH ADJUSTMENT NOTE: Do not apply pressure more than specified pressure. Radiator should be filled fully. 4. Inspect: Pressure Impossible to maintain the specified pres- sure for 10 seconds ¡ Repair. Radiator 1 Radiator hose joint 2 Coolant leakage ¡ Repair or replace. Radiator hose 3 Swelling ¡...
Page 151 REGLAGE DE L’EMBRAYAGE INSP EINSTELLUNG DER KUPPLUNG REGOLAZIONE DELLA FRIZIONE N.B.: HINWEIS: 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 152 THROTTLE CABLE ADJUSTMENT/ INSP THROTTLE LUBRICATION EC35A001 THROTTLE CABLE ADJUSTMENT 1. Check: Throttle grip free play a Out of specification¡Adjust. Throttle grip free play a a : 3~5 mm (0.12~0.20 in) 2. Adjust: Throttle grip free play Throttle grip free play adjustment steps: Loosen the locknut 1.
Page 153 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 154 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 155 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 156 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 157 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 Danni ¡ Sostituirlo. Endommagement¡Changer.
Page 158 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 159 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 160 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 161 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 162 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 en- gine runs at the lowest possible speed.
Page 163 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 164 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 165 (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 166 INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING Bleed the brake system if: The system has been disassembled. A brake hose has been loosened or removed. The brake fluid is very low. The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bleed.
Page 167 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 168 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 169 REGLAGE DE FREIN AVANT INSP EINSTELLUNG DER VORDERRADBREMSE REGOLAZIONE DEL FRENO ANTERIORE HINWEIS: 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 170 REAR BRAKE ADJUSTMENT/ INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364003 REAR BRAKE ADJUSTMENT 1. Check: Brake pedal height a Out of specification¡Adjust. Brake pedal height a a : Zero mm (Zero in) NOTE: The brake pedal height is the vertical distance from the inside top end of the footrest.
Page 171 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 IC364003 REGLAGE DU FREIN ARRIERE EINSTELLUNG DER HINTERRAD- REGOLAZIONE FRENO 1.
Page 172 INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT Loosen the pad pin 2. Remove the brake hose holder 3 and caliper 4 from the front fork. Remove the pad pin and brake pads 5. Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end.
Page 173 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 174 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT Install the pad pin plug w. Pad pin plug: 3 Nm (0.3 m•kg, 2.2 ft•lb) 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: Brake lever operation A softy or spongy feeling ¡ Bleed brake system.
Page 175 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 176 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT Remove the pad pin 6 and brake pads 7. Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. Loosen the bleed screw and push the caliper piston in.
Page 177 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 178 REAR BRAKE PAD INSULATOR INSPECTION INSP BRAKE FLUID LEVEL INSPECTION EC36b000 REAR BRAKE PAD INSULATOR INSPECTION 1. Remove: Brake pad Refer to “REAR BRAKE PAD INSPEC- TION AND REPLACEMENT” section. 2. Inspect: Rear brake pad insulator 1 Damage ¡ Replace. EC367001 BRAKE FLUID LEVEL INSPECTION 1.
Page 179 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 180 INSP SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION EC368000 SPROCKETS INSPECTION 1. Inspect: Sprocket teeth a Excessive wear ¡ Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set. EC369002 DRIVE CHAIN INSPECTION 1. Remove: Master link clip Joint 1 Drive chain 2 2.
Page 181 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 ¡...
Page 182 INSP DRIVE CHAIN SLACK ADJUSTMENT 5. Install: Drive chain 1 Joint 2 Master link clip 3 Be sure to install the master link clip to the direction as shown. a Turning direction 6. Lubricate: Drive chain Drive chain lubricant: SAE 10W-30 motor oil or suitable chain lubricants EC36A060 DRIVE CHAIN SLACK ADJUSTMENT...
Page 183 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 184 INSP FRONT FORK INSPECTION 3. Adjust: Drive chain slack Drive chain slack adjustment steps: Loosen the axle nut 1 and locknuts 2. Adjust chain slack turning adjusters 3. To tighten ¡ Turn adjuster 3 3 counter- clockwise. To loosen ¡ Turn adjuster 3 3 clockwise and push wheel forward.
Page 185 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 186 FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ INSP FRONT FORK INTERNAL PRESSURE RELIEVING/ FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1. Remove: Protector Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.
Page 187 NETTOYAGE DE BAGUE D’ETANCHETTE ET DE JOINT ANTIPOUSSIERE DE FOURCHE AVANT/ DECOMPRESSION INTERNE DE LA FOURCHE AVANT/ REGLAGE DE LA FORCE D’AMORTISSEMENT DE REBOND DE LA FOURCHE AVANT REINIGUNG DER ÖLDICHTUNG UND STAUBDICHTUNG DER VORDERRADGABEL/ VORDERRADGABEL-INNENDRUCKENTLASTUNG/ INSP EINSTELLUNG DER EXPANSIONS-DÄMPFUNGSKRAFT DER VORDERRADGABEL PULITURA DEL PARAOLIO E DEL PARAPOLVERE DELLA FORCELLA ANTERIORE/ COMPENSAZIONE DELLA PRESSIONE INTERNA DELLA FORCELLA ANTERIORE/ REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELL’ESTENSIONE DELLA FORCELLA ANTERIORE...
Page 188 FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT Extent of adjustment: Maximum Minimum 20 clicks out Fully turned in (from maximum position position) STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.
Page 189 REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION DE LA FOURCHE AVANT EINSTELLUNG DER KOMPRESSIONS-DÄMPFUNGSKRAFT DER VORDERRADGABEL INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELLA COMPRES- SIONE DELLA FORCELLA ANTERIORE Ampiezza della Einstellumfang: Etendue de réglage: regolazione: Maximum Minimum Maximum Minimum Massima Minima Voll 20 Raststellungen...
Page 190 INSP REAR SHOCK ABSORBER INSPECTION Extent of adjustment: Maximum Minimum 20 clicks out Fully turned in (from maximum position position) STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.
Page 191 VERIFICATION DE L’AMORTISSEUR ARRIERE INSP INSPEKTION DES HINTERRAD-STOSSDÄMPFERS ISPEZIONE DELL’AMMORTIZZATORE POSTERIORE Ampiezza della Einstellumfang: Etendue de réglage: regolazione: Maximum Minimum Maximum Minimum Massima Minima Voll 20 Raststellungen Position 20 le mettre hors Posizione 20 scatti in senso hineingedrehten herausdrehen complètement circuit (à...
Page 192 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: Rear frame 3. Loosen: Locknut 1 4. Adjust: Spring preload By turning the adjuster 2.
Page 193 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 194 REAR SHOCK ABSORBER REBOUND DAMPING INSP FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: 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 ¡...
Page 195 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 196 REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: Low compression damping force By turning the adjuster 1. Stiffer a a ¡ Increase the low compression damping force. (Turn the ad- juster 1 1 in.) Softer b b ¡...
Page 197 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 198 REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: High compression damping force By turning the adjuster 1. Stiffer a a ¡ Increase the high compression damping force. (Turn the ad- juster 1 1 in.) Softer b b ¡...
Page 199 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 200 TIRE PRESSURE CHECK/SPOKES INSPECTION AND INSP TIGHTENING/WHEEL INSPECTION EC36Q001 TIRE PRESSURE CHECK 1. Measure: Tire pressure Out of specification ¡ Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm , 15 psi) NOTE: Check the tire while it is cold. Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
Page 201 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 IC36Q001 CONTROLE DE PRESSION DES PRÜFUNG DES REIFENDRUCKS CONTROLLO DELLA PRESSIONE PNEUS...
Page 202 INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: Bearing free play Exist play ¡ Replace. EC36U013 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth.
Page 203 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. Esiste gioco ¡...
Page 204 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) Loosen the ring nut one turn. 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) Check the steering shaft by turning it lock to lock.
Page 205 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 206 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 207 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 208 INSP ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: Spark plug 2. Inspect: Electrode 1 Wear/Damage ¡ Replace. Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color ¡ Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become...
Page 209 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 210 INSP IGNITION TIMING CHECK EC372012 IGNITION TIMING CHECK 1. Remove: Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. Spark plug Crankcase cover (left) 2. Attach: Dial gauge 1 Spark plug hole dial stand 2 Dial gauge: YU-3097/90890-01252 Spark plug hole dial stand:...
Page 211 CONTROLE ET REGLAGE DE L’AVANCE A L’ALLUMAGE INSP PRÜFUNG UND EINSTELLUNG DER ZÜNDZEITPUNKT CONTROLLO DELLA MESSA IN FASE DELL’ACCENSIONE IC372012 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 212 INSP IGNITION TIMING CHECK 7. Adjust: Ignition timing Adjustment steps: Loosen the screws (stator) 1. Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator. Tighten the screws (stator). Screw (stator): 8 Nm (0.8 m•kg, 5.8 ft•lb) 3-40...
Page 213 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 214 SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS 19 Nm (1.9 m•kg, 13 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 19 Nm (1.9 m•kg, 13 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb)
Page 215 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 216 SEAT, FUEL TANK AND SIDE COVERS EC4R3000 REMOVAL POINTS EC413110 Side cover 1. Remove: Bolt (side cover) Side cover (left and right) 1 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air cleaner case.
Page 217 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 IC413110 Couvercle latéral Seitendeckel Copertura laterale 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Boulon (couvercle latéral) 9 Bullone (copertura laterale) 9 Schraube (seitendeckel) 9 Couvercle latéral (gauche et...
Page 218 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) 10 Nm (1.0 m•kg, 7.2 ft•lb) 12 Nm (1.2 m•kg, 8.7 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 219 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 220 RADIATOR EC450001 RADIATOR 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 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...
Page 221 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 222 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 223 RADIATEUR KÜHLER RADIATORE IC456000 REMARQUES HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO CONCERNANT LA MANIPULATION Wenn der Motor und der Kühler Non togliere il tappo del radiatore heiß sind, darf niemals der Künler- quando il motore e il radiatore sono caldi. Sotto pressione possono essere deckel entfernt werden.
Page 224 RADIATOR EC455000 ASSEMBLY AND INSTALLATION EC445342 Radiator 1. Install: Radiator breather hose 1 Radiator hose 3 2 1 Nm (0.1 m•kg, 0.7 ft•lb) Radiator hose 1 3 1 Nm (0.1 m•kg, 0.7 ft•lb) To radiator (right) 4. 2. Install: Radiator (right) 1 Bolt [radiator (right)] 2 Radiator hose 4 3 1 Nm (0.1 m•kg, 0.7 ft•lb)
Page 225 RADIATEUR KÜHLER RADIATORE IC455000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E Kühler MONTAGE INSTALLAZIONE 1. Einbauen: Radiateur IC455342 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 226 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 227 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 228 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 229 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 230 CARBURETOR AND REED VALVE EC466030 HANDLING NOTE Do not disassemble the venturi block and main nozzle 2 2 because it will cause a drop in carburetor performance. EC463000 REMOVAL POINTS EC463110 Throttle valve 1. Remove: Throttle valve 1 Ring 2 Spring (throttle valve) 3 Mixing chamber top 4 Throttle cable 5...
Page 231 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 questo provocherebbe un calo di ren- Leistungsabfall...
Page 232 CARBURETOR AND REED VALVE 2. Inspect: Main jet 1 Main jet holder 2 Pilot jet 3 Contamination ¡ Clean. NOTE: Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. Never use a wire. EC464200 Needle valve 1.
Page 233 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 Getto pilota 3 9 Leerlaufdüse 3...
Page 234 CARBURETOR AND REED VALVE EC464A00 Filter 1. Inspect: Filter 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: Fuel level a Out of specification ¡...
Page 235 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. HINWEIS: NOTA: N.B.: Filter beim Einbau in den Vergaser Ispezionare il filtro così...
Page 236 CARBURETOR AND REED VALVE EC464600 Float 1. Inspect: Float 1 Damage ¡ Replace. EC464701 Reed valve 1. Measure: Reed valve bending a Out of specification ¡ Replace. Reed valve bending limit: 0.2 mm (0.008 in) Valve stopper height b Out of specification ¡Adjust stopper/ Replace valve stopper.
Page 237 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC464600 Flotteur Galleggiante Schwimmer 1. Examiner: 1. Prüfen: 1. Ispezionare 9 Galleggiante 1 9 Flotteur 1 9 Schwimmer 1 Danni¡Sostituirlo. Endommagement¡Changer. Beschädigung¡Erneuern. IC464701 Soupape flexible Zungenventil Valvola a lamella 1.
Page 238 CARBURETOR AND REED VALVE 2. Install: Reed valve assembly 1 Reed valve spacer 2 NOTE: Install the reed valve spacer with its wider con- tact surface side a to the right. 3. Install: Carburetor joint 1 Bolt (carburetor joint) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) EC4652C2 Carburetor...
Page 239 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 240 CARBURETOR AND REED VALVE 3. Install: Main jet holder 1 Main jet 2 Pilot jet 3 Valve seat 4 Screw (valve seat) 5 4. Install: Needle valve 1 Float 2 Float pin 3 Screw (float pin) 4 Needle jet cover 5 NOTE: After installing the needle valve to the float, in- stall them to the carburetor.
Page 241 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 Getto pilota 3...
Page 242 CARBURETOR AND REED VALVE 7. Install: Throttle cable 1 Mixing chamber top 2 Spring (throttle valve) 3 Ring 4 Throttle valve 5 NOTE: While compressing the spring, connect the throttle cable. Align the projection a on the ring with the groove b in the needle holder 6.
Page 243 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 Molla (valvola regolatrice del 9 Feder (Drosselventil) 3...
Page 244 CARBURETOR AND REED VALVE 2. Tighten: Screw (air filter joint) 1 Screw (carburetor joint) 2 3. Clamp: Air vent hose 1 Overflow hose 2 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 4. Adjust: Idle speed Refer to “IDLE SPEED ADJUSTMENT” section in the CHAPTER 3.
Page 245 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 Vite (giunto del carburatore) 2 9 Schraube (Vergaserverbin-...
Page 246 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 247 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 248 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 249 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 250 CYLINDER HEAD, CYLINDER AND PISTON EC473000 REMOVAL POINTS EC473210 Push rod 1. Remove: Bolt (push rod) 1 Push rod 2 NOTE: Set the collar 3 included in owner’s tool kit to remove the bolt (push rod). EC473402 Piston and piston ring 1.
Page 251 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 Schubstange Asta di spinta 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Boulon 9 Bullone (asta di spinta) 1 9 Schraube (Schubstange) 1 (champignon débrayage) 1...
Page 252 CYLINDER HEAD, CYLINDER AND PISTON EC474000 INSPECTION EC474101 Cylinder head 1. Remove: Carbon 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: Cylinder head water jacket ¡...
Page 253 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474000 VERIFICATION INSPEKTION ISPEZIONE IC474101 Culasse Zylinderkopf Testa cilindro 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 254 CYLINDER HEAD, CYLINDER AND PISTON 2. Inspect: Cylinder inner surface Score marks ¡ Repair or replace. Use #400~600 grit wet sandpaper. Do not rebore the cylinder. 3. Measure: Cylinder bore “C” Use cylinder gauge 1. Out of limit ¡ Replace. NOTE: Measure the cylinder bore “C”...
Page 255 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 256 CYLINDER HEAD, CYLINDER AND PISTON EC474402 Piston pin and small end bearing 1. Inspect: Piston pin Small end bearing Signs of heat discoloration ¡ Replace. 2. Measure: Piston pin outside diameter Use micrometer 1. Out of limit ¡ Replace. Piston pin outside diameter: Standard <Limit>...
Page 257 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474402 Axe de piston et coussinet de pied de Spinotto e cuscinetto dell’estremità Kolbenbolzen und Pleuelfußlager bielle 1. Prüfen: piccola 9 Kolbenbolzen 1. Examiner: 1. Ispezionare: 9 Axe de piston 9 Spinotto 9 Pleuelfußlager 9 Coussinet de pied de bielle...
Page 258 CYLINDER HEAD, CYLINDER AND PISTON EC474502 Piston ring 1. Install: Piston ring Into the cylinder. Push the ring with the piston crown. 2. Measure: End gap Use a thickness gauge 1. Out of limit ¡ Replace. Ring end gap (installed): Standard <Limit>...
Page 259 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474502 Segment Fascia elastica Kolbenring 1. Monter: 1. Ausbauen: 1. Installare: 9 Fascia elastica 9 Segment 9 Kolbenring Nel cilindro. Dans le cylindre. In Zylinder. Pousser le segment avec la Den Kolbenring mit dem Kol- Spingere la fascia con la corona calotte du piston.
Page 260 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: Cylinder 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 261 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 262 CYLINDER HEAD, CYLINDER AND PISTON EC474830 Power valve 1. Inspect: Power valve 1,2 1 Wear/Damage ¡ Replace. Carbon deposits ¡Remove. Link lever 2 Valve shaft 3 Collar 4 Wear/Damage ¡ Replace. Spring 5 Broken ¡ Replace. EC474901 Power valve hole on cylinder 1.
Page 263 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474830 Clapet de puissance Valvola di potenza Leistungsventil 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 Usura/Danni¡Sostituirla.
Page 264 CYLINDER HEAD, CYLINDER AND PISTON 2. Install: Spring 1 Link lever 2 Collar 3 Valve shaft 4 Bolt (link lever) 5 4 Nm (0.4 m•kg, 2.9 ft•lb) NOTE: Install the spring to the link lever, and then to the cylinder. Install the spring with its stopper portion a fac- ing inward.
Page 265 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 Piattello 3 9 Hülse 3...
Page 266 CYLINDER HEAD, CYLINDER AND PISTON EC475233 Piston ring and piston 1. Install: Piston ring 1 NOTE: Take care not to scratch the piston or damage the piston ring. Align the piston ring gap with the pin 2. After installing the piston ring, check the smooth movement of it.
Page 267 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC475232 Segment et piston Fascia elastica e pistone Kolbenring und Kolben 1. Monter: 1. Ausbauen: 1. Installare: 9 Fascia elastica 1 9 Segment 1 9 Kolbenring 1 N.B.: HINWEIS: NOTA:...
Page 268 CYLINDER HEAD, CYLINDER AND PISTON EC4753A1 Cylinder head and cylinder 1. Apply: Engine oil To piston 1, piston ring 2 and cylinder surface. 2. Install: Cylinder 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 269 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC4753A1 Culasse et cylindre Testa cilindro e cilindro Zylinderkopf und Zylinder 1. Appliquer: 1. Auftragen: 1. Applicare: 9 Olio per motori 9 Huile du moteur 9 Motoröl Sur le piston 1, le segment 2 Sul pistone 1, sulla fascia ela- Auf Kolben 1, Kolbenring 2...
Page 270 CYLINDER HEAD, CYLINDER AND PISTON 5. Install: Gasket (power valve housing) Power valve housing 1 Bolt (power valve housing) 2 5 Nm (0.5 m•kg, 3.6 ft•lb) 6. Install: O-ring 1 NOTE: Apply the lithium soap base grease on the O- rings.
Page 271 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 Corpo della valvola di potenza 9 Leistungsventilgehäuse 1 9 Schraube...
Page 272 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 273 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 274 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 275 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 Ecrou (noix d’embrayage) ...
Page 276 CLUTCH AND PRIMARY DRIVEN GEAR EC493000 å å REMOVAL POINTS EC483211 Clutch boss 1. Remove: Nut 1 Lock washer 2 Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4, 5 to hold the clutch boss. ∫...
Page 277 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 Kupplungsnabe Mozzo della frizione 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 278 CLUTCH AND PRIMARY DRIVEN GEAR EC484500 Friction plate 1. Measure: Friction 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 279 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC484500 Disque de friction Disco di innesto Reibscheibe 1. Mesurer: 1. Messen: 1. Misurare: 9 Spessore del disco di innesto 9 Epaisseur de disque de friction 9 Reibscheibendicke Fuori specifica¡Sostituire Hors-spécification¡...
Page 280 CLUTCH AND PRIMARY DRIVEN GEAR EC495000 ASSEMBLY AND INSTALLATION EC495240 Clutch 1. Install: Thrust plate [ φ 36 mm (1.42 in)] 1 Spacer 2 Bearing 3 Primary driven gear 4 NOTE: Apply the transmission oil on the spacer, bearing and primary driven gear inner circumference. 2.
Page 281 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 [ φ 36 mm (1,42 Frizione 1. Monter: in)] 1 9 Plaque de botée [ φ...
Page 282 CLUTCH AND PRIMARY DRIVEN GEAR 5. Install: Friction plate 1 1 Clutch plate 2 Friction plate 2 3 NOTE: Install the clutch plates and friction plates alter- nately on the clutch boss, starting with a friction plate and ending with a friction plate. Use the friction plates 1 for the first and final while paying attention to the difference in sur- face pattern.
Page 283 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 Disco di innesto 2 3...
Page 284 CLUTCH AND PRIMARY DRIVEN GEAR 9. Install: Gasket (clutch cover) 1 NOTE: Position the rack a on the push rod backward. 10. Install: Clutch cover 1 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 285 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 N.B.: HINWEIS: NOTA: Placer le support a en arrière sur la Posizionare la cremagliera a sull’asta Die Zahnstange a und die Schub- tige poussoir.
Page 286 CLUTCH AND PRIMARY DRIVEN GEAR 4. Install: Plain washer 1 Circlip 2 4-37...
Page 287 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 288 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 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 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 290 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 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 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 292 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C3000 REMOVAL POINTS EC483111 Primary drive gear 1. Loosen: Bolt (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 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 IC4C3000 PUNTI DI RIMOZIONE POINTS DE DEPOSE AUSBAUPUNKTE IC483111 Ingranaggio conduttore primario Pignon de transmission primaire Primärantriebszahnrad 1.
Page 294 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4B4300 Kick gear clip 1. Measure: Kick 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: Shift shaft 1 Bend/Damage ¡...
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 IC4B4300 Agrafe de pignon de démarreur au Fermaglio a graffa dell’ingranaggio Kickstarter-Zahnradklemme della pedivella pied 1.
Page 296 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C5000 ASSEMBLY AND INSTALLATION EC4C5120 Stopper lever 1. Install: Torsion spring 1 Stopper lever 2 Spacer 3 Bolt (stopper lever) 4 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Align the stopper lever roller with the slot on segment.
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 IC4C5000 REMONTAGE ET MONTAGGIO E MONTAGE UND EINBAU INSTALLAZIONE MONTAGE IC4C5120 Anschlaghebel Leva di fermo Levier de butée 1.
Page 298 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 4. Install: Bolt (shift guide) 1 10 Nm (1.0 m•kg, 7.2 ft•lb) EC4C5301 Shift shaft 1. Install: Roller 1 Shift shaft 2 NOTE: Apply the transmission oil on the roller and shift shaft.
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 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 300 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 4. Hook: Torsion spring 1 NOTE: Turn the torsion spring clockwise and hook into the proper hole a in the crankcase. EC4C5402 Kick idle gear 1. Install: Circlip 1 Kick idle gear 2 Plain washer 3 NOTE: Apply the transmission oil on the kick idle gear...
Page 301 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.: HINWEIS:...
Page 302 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 5. Install: Crankcase cover (right) 1 NOTE: Position the rack a on the push rod backward. Mesh the governor gear 2, and impeller shaft gear 3 with primary drive gear 4. 6. Install: Bolt [crankcase cover (right)] 1 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE:...
Page 303 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 304 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 305 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 306 YPVS GOVERNOR EC4K3000 REMOVAL POINTS EC4K3100 Governor 1. Remove: Dowel pin 1 NOTE: While compressing the spring, remove the dowel pin. EC4K4000 INSPECTION EC4K4100 Governor groove 1. Inspect: Plain washer 1 Collar 2 Wear/Damage ¡ Replace. EC4K4200 Bearing 1. Inspect: Thrust bearing 1 Plain washer 2 Wear/Damage ¡...
Page 307 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.: HINWEIS: Togliere il perno di riferimento compri- Déposer le goujon tout en comprimant Die Feder zusammendrüken, und den mendo la molla.
Page 308 YPVS GOVERNOR 2. Install: Ball 1 Retainer 2 To governor shaft 3. NOTE: Apply the transmission oil on the retainer and ball. 3. Install: Dowel pin 1 NOTE: While compressing the spring, install the dowel pin. Make sure the dowel pin fits into the groove a in the retainer.
Page 309 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. Sull’albero del regolatore 3. Zur Reglerachse 3 N.B.: HINWEIS: NOTA:...
Page 310 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 311 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 312 WATER PUMP EC4G3000 REMOVAL POINTS EC4G3110 Impeller shaft 1. Remove: Impeller 1 Plain washer 2 Impeller 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 313 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 314 WATER PUMP EC444300 Impeller shaft gear 1. Inspect: Gear teeth a Wear/Damage ¡ Replace. EC4H4600 Bearing 1. Inspect: Bearing 1 Rotate inner race with a finger. Rough spot/Seizure ¡ Replace. EC444400 Oil seal 1. Inspect: Oil seal 1 Wear/Damage ¡ Replace. EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111...
Page 315 POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA IC444300 Pignon d’axe de turbine Ingranaggio dell’albero del girante Flügelradwellenzahnrad 1. Examiner: 1. Ispezionare: 1. Prüfen: 9 Denti dell’ingranaggio a 9 Dents a 9 Zähne a Usura/Danni¡Sostituirli. Usure/endommagement¡ Abnutzung/Beschädigung¡ Changer. Erneuern. IC4H4600 Roulement Cuscinetto Lager 1.
Page 316 WATER PUMP EC4G5220 Impeller shaft 1. Install: Impeller shaft 1 NOTE: Take care so that the oil seal lip is not dam- aged or the spring does not slip off its position. When installing the impeller shaft, apply the lithium soap base grease on the oil seal lip and impeller shaft.
Page 317 POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA IC4G5220 Axe de turbine Albero del girante Flügelradwelle 1. Monter: 1. Einbauen: 1. Installare: 9 Albero del girante 1 9 Axe de turbine 1 9 Flügelradwelle 1 N.B.: NOTA: HINWEIS: 9 Prendre garde à ne pas endommager 9 Fare attenzione che il labbro del 9 Darauf achten, daß...
Page 318 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 319 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 320 CDI MAGNETO EC4L3000 REMOVAL POINTS EC4L3102 Rotor 1. Remove: Nut (rotor) 1 Plain washer 2 Use the rotor holding tool 3. Rotor holding tool: YU-1235/90890-01235 2. Remove: Rotor 1 Use the flywheel puller 2. Flywheel puller: YM-1189/90890-01189 NOTE: When installing the flywheel puller, turn it coun- terclockwise.
Page 321 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 322 CDI MAGNETO 2. Install: Woodruff key 1 Rotor 2 NOTE: Clean the tapered portions of the crankshaft and rotor. When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b. When installing the rotor, align the keyway c of the rotor with the woodruff key.
Page 323 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.: NOTA: HINWEIS: 9 Nettoyer la paritie conique de l’extré- 9 Pulire le parti coniche dell’albero a 9 Den Kegeligen Teil des Kurbelwel- mité...
Page 324 CDI MAGNETO 7. Connect: CDI magneto lead 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 8. Install: Gasket [crankcase cover (left)] Crankcase cover (left) 1 Screw [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 325 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 326 ENGINE REMOVAL EC4M0000 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) Extent of removal Order...
Page 327 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 328 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 329 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  Ecrou (pignon d’entraînement)  Rondelle-frein Se reporter à “POINTS DE DEPOSE”. ...
Page 330 ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: Nut (drive sprocket) 1 Lock washer 2 NOTE: Straighten the lock washer tab. Loosen the nut while applying the rear brake. 2. Remove: Drive sprocket 1 Drive chain 2 NOTE: Remove the drive sprocket together with the dri- ve chain.
Page 331 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 332 ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION EC4M5171 Engine installation 1. Install: Engine 1 Install the engine from right side. Pivot shaft 2 85 Nm (8.5 m•kg, 61 ft•lb) Engine mounting bolt (lower) 3 69 Nm (6.9 m•kg, 50 ft•lb) Engine mounting bolt (front) 4 69 Nm (6.9 m•kg, 50 ft•lb) Engine bracket 5 Bolt (engine bracket) 6...
Page 333 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 334 ENGINE REMOVAL 2. Install: Lock washer 1 Nut (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: Chain cover 1 Screw (chain cover) 2 5 Nm (0.5 m•kg, 3.6 ft•lb) 4-61...
Page 335 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) HINWEIS:...
Page 336 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 337 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 338 CRANKCASE AND CRANKSHAFT EC4N3000 REMOVAL POINTS EC4N3100 Segment 1. Remove: Bolt (segment) 1 Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt. EC4N3212 Crankcase 1. Remove: Crankcase (right) 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 NOTE:...
Page 339 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 340 CRANKCASE AND CRANKSHAFT EC4N3302 Crankshaft 1. Remove: Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 NOTE: Make appropriate bolts 3 as shown available by yourself and attach the tool with them. Do not use a hammer to drive out the crankshaft.
Page 341 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N3302 Vilebrequin Albero a gomiti Kurbelwelle 1. Déposer: 1. Togliere: 1. Ausbauen: 9 Albero a gomiti 1 9 Vilebrequin 1 9 Kurbelwelle 1 Usare l’utensile per separare il Utilisez le séparateur de carter Kurbelgehäuse-Trennwerkzeug carter 2.
Page 342 CRANKCASE AND CRANKSHAFT 2. Inspect: Bearings 1 Rotate inner race with a finger. Rough spot/Seizure ¡ Replace. 3. Inspect: Oil seal 1 Damage ¡ Replace. EC4N4202 Crankshaft 1. Measure: Runout limit a Small end free play limit b Connecting rod big end side clearance c Crank width d Out of specification ¡...
Page 343 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 344 CRANKCASE AND CRANKSHAFT EC4N5102 Oil seal 1. Install: Oil seal (left) 1 Oil seal (right) 2 NOTE: Apply the lithium soap base grease on the oil seal lip. Install the oil seal with its manufacture’s marks or numbers facing outward. EC4N5272 Crankshaft 1.
Page 345 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N5102 Bague d’étanchéité Paraolio Öldichtung 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 346 Unsmooth operation ¡ Repair. 3. Apply: Sealant 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: Dowel pin 1...
Page 347 ® 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: HINWEIS: Nettoyer la surface de contact des Pulire la superficie di contatto del carter demi-carters (gauche et droit) avant Die Kontaktfläche des Kurbelgehäu-...
Page 348 CRANKCASE AND CRANKSHAFT 6. Install: Holder 1 Bolt (holder) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) 7. Install: Segment 1 Bolt (segment) 2 30 Nm (3.0 m•kg, 22 ft•lb) NOTE: When installing the segment onto the shift cam 3, align the punch mark a with the dowel pin Turn the segment clockwise until it stops and tighten the bolt.
Page 349 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 350 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK 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...
Page 351 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 352 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS EC4H3200 Transmission 1. Remove: Main axle 1 Drive axle 2 NOTE: Tap lightly on the transmission drive axle with a soft hammer to remove. Remove assembly carefully. Note the position of each part. Pay particular attention to the lo- cation and direction of shift forks.
Page 353 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 354 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4801 Shift fork, shift cam and segment 1. Inspect: Shift fork 1 Wear/Damage/Scratches ¡ Replace. 2. Inspect: Shift cam 1 Segment 2 Guide bar 3 Bend/Wear/Damage ¡ Replace. 3. Check: Shift fork movement On its guide bar. Unsmooth operation ¡...
Page 355 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 Forcella del cambio, camma del cam- Schaltgabel, Schaltnocke und Segment bio e segmento segment 1.
Page 356 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: 3rd wheel gear (29T) 1 4th wheel gear (24T) 2 2nd wheel gear (31T) 3 5th wheel gear (25T) 4 1st wheel gear (27T) 5 To drive axle 6. NOTE: Apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circumference and on the end surface.
Page 357 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 3è (29D) 1 9 Ingranaggio a ruota 3 (29T) 1 Zahnrad für 3. Gang (29Z) 1 9 Roue de 4è...
Page 358 TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: Main axle 1 Drive axle 2 NOTE: Apply the transmission oil on the crankcase bearings. EC4H5312 Shift cam and shift fork 1. Install: Shift fork 1 (L) 1 Shift fork 2 (C) 2 Shift fork 3 (R) 3 NOTE: Mesh the shift fork #1 (L) with the 4th wheel...
Page 359 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO 5. Monter: 5. Einbauen: 5. Installare: 9 Axe principal 1 9 Asse principale 1 Hauptwelle 1 9 Axe moteur 2 Vorgelegewelle 2 9 Asse motore 2 N.B.:...
Page 360 TRANSMISSION, SHIFT CAM AND SHIFT FORK 4. Check: Shifter operation Transmission operation Unsmooth operation ¡ Repair. 4-74...
Page 361 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO 4. Contrôler: 4. Kontrollieren: 4. Controllare: 9 Fonctionnement de sélecteur 9 Funzionamento del cambio Funktion der Gangschaltung 9 Fonctionnement 9 Funzionamento della trasmissio- boîte à...
Page 362 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 363 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 364 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 365 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 366 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: Bearing 1 NOTE: Remove the bearing using a general bearing puller 2.
Page 367 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.: HINWEIS:...
Page 368 CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: Wheel axle bends Out of specification ¡ Replace. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading.
Page 369 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 ¡...
Page 370 CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION EC595101 Front wheel 1. Install: Bearing (left) 1 Spacer 2 Bearing (right) 3 Oil seal 4 NOTE: Apply the lithium soap base grease on the bearing and oil seal lip when installing. Use a socket that matches the outside diam- eter of the race of the bearing.
Page 371 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 372 CHAS FRONT WHEEL AND REAR WHEEL 5. Install: Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. 6. Install: Nut (wheel axle) 1 105 Nm (10.5 m•kg, 75 ft•lb) 7. Tighten: Bolt (axle holder) 1 23 Nm (2.3 m•kg, 17 ft•lb) NOTE: Before tightening the bolt, fit the wheel axle to...
Page 373 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.: HINWEIS: NOTA: 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 374 CHAS FRONT WHEEL AND REAR WHEEL 9. Install: Hose cover 1 Plain washer 2 Bolt [hose cover (M8)] 3 16 Nm (1.6 m•kg, 11 ft•lb) Bolt [hose cover (M6)] 4 7 Nm (0.7 m•kg, 5.1 ft•lb) EC5251A0 Rear wheel 1. Install: Bearing (right) 1 Circlip 2 Spacer 3...
Page 375 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 Bullone [copertura del tubo fles-...
Page 376 CHAS FRONT WHEEL AND REAR WHEEL 3. Install: Driven sprocket 1 Bolt (driven sprocket) 2 Plain washer (driven sprocket) 3 Nut (driven sprocket) 4 42 Nm (4.2 m•kg, 30 ft•lb) NOTE: Tighten the nuts in stage, using a crisscross pat- tern.
Page 377 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 378 CHAS FRONT WHEEL AND REAR WHEEL 8. Install: Chain puller (right) 1 Plain washer 2 Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point. 9. Adjust: Drive chain slack a Drive chain slack : 40~50 mm (1.6~2.0 in) Refer to “DRIVE CHAIN SLACK ADJUSTMENT”...
Page 379 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 380 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 381 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 382 CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE 7 Nm (0.7 m•kg, 5.1 ft•lb) 2 Nm (0.2 m•kg, 1.4 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 3 Nm (0.3 m•kg, 2.2 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 383 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 384 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 385 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 386 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 387 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 388 CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 REMOVAL POINTS EC5A3100 Brake fluid 1. Remove: [Front] Master cylinder cap 1 [Rear] Reservoir tank cap 1 Protector 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 389 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 [Avant] [Vorne] 1. Togliere: 9 Coupelle du maître-cylindre 1 9 Hauptbremszylinderkappe 1 [Anteriormente] [Arrière]...
Page 390 CHAS FRONT BRAKE AND REAR BRAKE EC533402 Piston seal kit 1. Remove: Dust seal 1 Piston 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 391 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 Joint de piston 2 9 Parapolvere 1 9 Kolbendichtung 2...
Page 392 CHAS FRONT BRAKE AND REAR BRAKE EC534214 Caliper 1. Inspect: Caliper cylinder inner surface a Wear/Score marks¡Replace caliper as- sembly. A Front B Rear 2. Inspect: Caliper piston 1 Wear/Score marks¡Replace caliper piston assembly. Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled.
Page 393 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 394 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Piston seal 1 Dust 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 395 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 396 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Copper washer 1 Union 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 397 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 398 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Disc cover 1 Bolt (disc cover) 2 7 Nm (0.7 m•kg, 5.1 ft•lb) 3. Install: Copper washer 1 Brake hose 2 Union bolt 3 30 Nm (3.0 m•kg, 22 ft•lb) 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 399 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 400 CHAS FRONT BRAKE AND REAR BRAKE EC5A5220 Master cylinder kit 1. Clean: Master cylinder Master cylinder kit Clean them with brake fluid. 2. Install: Master cylinder cup (primary) 1 Master cylinder cup (secondary) 2 To master cylinder piston 3. NOTE: Apply the brake fluid on the master cylinder cup.
Page 401 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 402 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: [Front] Master cylinder kit 1 Plain washer 2 Circlip 3 Master cylinder boot 4 To master cylinder 5. [Rear] Master cylinder kit 1 Push rod 2 Circlip 3 Master cylinder boot 4 To master cylinder 5.
Page 403 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 Rosetta 2 9 Beilegescheibe 2 9 Circlip 3...
Page 404 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake lever 1 Bolt (brake lever) 2 6 Nm (0.6 m•kg, 4.3 ft•lb) Nut (brake lever) 3 6 Nm (0.6 m•kg, 4.3 ft•lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston.
Page 405 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 406 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Pin 1 Plain washer 2 Cotter 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: Brake hose 1 10 Nm (1.0 m•kg, 7.2 ft•lb) To brake hose holder 2.
Page 407 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 Coppiglia 3 9 Splint 3 N.B.:...
Page 408 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Copper washer 1 Brake hose 2 Union bolt 3 30 Nm (3.0 m•kg, 22 ft•lb) 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 409 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 Bullone di unione 3...
Page 410 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake hose holder 1 Screw (brake hose holder) 2 2 Nm (0.2 m•kg, 1.4 ft•lb) 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 411 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 9 Vite (supporto del tubo flessibi-...
Page 412 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: Brake system Refer to “BRAKE SYSTEM AIR BLEED- ING” section in the CHAPTER 3. 3. Inspect: Brake fluid level Fluid at lower level¡Fill up. Refer to “BRAKE FLUID LEVEL INSPEC- TION” section in the CHAPTER 3. 4.
Page 413 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 414 CHAS FRONT FORK EC550000 FRONT FORK 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 415 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 416 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 417 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 418 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: The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to...
Page 419 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC556000 REMARQUES HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO CONCERNANT LA HINWEIS: 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 420 CHAS FRONT FORK EC553201 Inner tube 1. Remove: Dust seal 1 Stopper ring 2 Using slotted-head screwdriver. Take care not to scratch the inner tube. 2. Remove: Inner tube 1 Oil seal removal steps: a the inner tube just be- Push in slowly fore it bottoms out and then pull it back quickly b.
Page 421 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 422 CHAS FRONT FORK EC554200 Base valve 1. Inspect: Valve assembly 1 Wear/Damage¡Replace. O-ring 2 Damage¡Replace. EC554400 Fork spring 1. Measure: Fork spring free length a Out of specification¡Replace. Fork spring free length: Standard <Limit> 460 mm 455 mm (18.1 in) (17.9 in) EC554502 Inner tube...
Page 423 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC554200 Soupare de base Valvola di base Hauptventil 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Gruppo valvola 1 9 Ensemble clapet 1 9 Ventileinheit 1 Usura/Danni¡Sostituirlo. Usure/endommagement Abnutzung/Beschädigung ¡Changer. ¡Erneuern. 9 Anello di tenuta 2 9 Joint torique 2 9 O-Ring 2 Danni¡Sostituirlo.
Page 424 CHAS FRONT FORK EC554700 Cap bolt 1. Inspect: Cap bolt 1 O-ring 2 Air 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: Damper rod 1 To inner tube 2.
Page 425 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 426 CHAS FRONT FORK 5. Install: Spring guide 1 Locknut 2 To damper rod 3. NOTE: Install the spring guide with its cut a facing upward. With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6.
Page 427 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. Sulla barra dello smorzatore 3. Zum Dämpfungsstange 3.
Page 428 CHAS FRONT FORK 9. Install: Slide metal 1 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: Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2.
Page 429 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 430 CHAS FRONT FORK 13. Check: Inner tube smooth movement Tightness/Binding/Rough spots ¡ Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: Front fork oil Until outer tube top surface with recom- mended fork oil 1. Recommended oil: Suspension oil “01”...
Page 431 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¡Ripetere le operazio- holen.
Page 432 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 433 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 434 CHAS FRONT FORK 21. Measure: Distance 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: Rebound damping adjuster 1 NOTE: Loosen the rebound damping adjuster finger tight.
Page 435 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 436 CHAS FRONT FORK 26. Tighten: Cap bolt (locknut) 1 29 Nm (2.9 m•kg, 21 ft•lb) NOTE: While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4. Hold the locknut 5 and tighten the cap bolt with specified torque.
Page 437 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 26. Serrer: 26. Festziehen: 26. Serrare: 9 Boulon capuchon 1 9 Vite mordente (controdado) 1 9 Hutschraube 1 29 Nm (2,9 m•kg, 21 ft•lb) ft•lb) 29 Nm (2,9 m•kg, 21 ft•lb) 29 Nm (2,9 m•kg, 21 HINWEIS: N.B.: NOTA:...
Page 438 CHAS FRONT FORK 4. Tighten: Pinch bolt (handle crown) 1 23 Nm (2.3 m•kg, 17 ft•lb) Pinch 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 439 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 Klemmschraube...
Page 440 CHAS HANDLEBAR EC5B0000 HANDLEBAR 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...
Page 441 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 442 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 443 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 444 CHAS HANDLEBAR EC5B3000 REMOVAL POINTS EC5B3100 Master cylinder 1. Remove: Master cylinder bracket 1 Master cylinder 2 Do not let the master cylinder hang on the brake hose. Keep the master cylinder cap side horizon- tal to prevent air from coming in. EC5B3200 Grip 1.
Page 445 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 446 CHAS HANDLEBAR 2. Install: Grip cap (upper) 1 Grip cap (lower) 2 Bolt (grip cap) 3 NOTE: Temporarily tighten the bolts (grip cap). EC5B5210 Handlebar 1. Install: Handlebar 1 Handlebar holder 2 Bolt (handlebar holder) 3 28 Nm (2.8 m•kg, 20 ft•lb) NOTE: The upper handlebar holder should be installed with the punched mark a forward.
Page 447 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 Calotta della manopola (inferio- 9 Schraube (Griffkappe) 3 re) 2 HINWEIS:...
Page 448 CHAS HANDLEBAR 4. Install: Throttle 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: Roller 1 Collar 2 NOTE: Apply the lithium soap base grease on the roller sliding surface.
Page 449 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. N.B.: HINWEIS: NOTA: Appliquer de la graisse à base de savon Applicare sull’estremità...
Page 450 CHAS HANDLEBAR 10. Install: Bolt (grip cap) 1 4 Nm (0.4 m•kg, 2.9 ft•lb) a a and Install the grip cap so that the gaps 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 451 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 452 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 453 GUIDON LENKSTANGE CHAS MANUBRIO 14. Fixer la partie de fixation a de la 14. Bloccare la parte della brida a 14. Das Klemmteil plaque d’immatriculation au gui- Nummernschildes della targa sul manubrio. Lenkstange festklemmen. don. 15. Inserire l’estremità dello sfiato del carburante 1 nel foro della targa.
Page 454 CHAS STEERING EC560000 STEERING 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 455 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 456 CHAS STEERING EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: 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: Bearing (lower) 1 Use the floor chisel 2.
Page 457 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 458 CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a sol- vent. 2. Inspect: Bearing 1 Ball race Pitting/Damage ¡ Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand.
Page 459 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 460 CHAS STEERING 4. Install: Plain washer 1 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. Check the steering shaft by turning it lock to lock.
Page 461 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 462 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: Front fork top end a Front fork top end (standard) a a : 5 mm (0.20 in) 11.
Page 463 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 464 CHAS SWINGARM EC570000 SWINGARM 53 Nm (5.3 m•kg, 38 ft•lb) 19 Nm (1.9 m•kg, 13 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 85 Nm (8.5 m•kg, 61 ft•lb) 80 Nm (8.0 m•kg, 58 ft•lb) 1 Swingarm removal Extent of removal: Extent of removal Order Part name...
Page 465 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 466 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY 80 Nm (8.0 m•kg, 58 ft•lb) 6 Nm (0.6 m•kg, 4.3 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 467 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 468 CHAS SWINGARM EC573000 REMOVAL POINTS EC573201 Bearing 1. Remove: Bearing 1 NOTE: Remove the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes, collars, and covers in a solvent. EC574111 Swingarm 1. Inspect: Bearing 1 Bush 2 ¡...
Page 469 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE IC573000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC573201 Cuscinetto Roulement Lager 1. Togliere: 1. Déposer: 1. Ausbauen: 9 Cuscinetto 1 9 Roulement 1 9 Lager 1 NOTA: N.B.: HINWEIS: Togliere il cuscinetto premendone Déposez le roulement en appuyant sur Lager durch Drücken auf den äusse- l’anello esterno.
Page 470 CHAS SWINGARM EC575000 ASSEMBLY AND INSTALLATION EC575202 Bearing and oil seal 1. Install: Bearing 1 Oil seal 2 To swingarm. NOTE: Apply the molybdenum disulfide grease on the bearing when installing. Install the bearing by pressing it on the side having the manufacture's marks or numbers.
Page 471 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 472 CHAS SWINGARM EC5751B2 Swingarm 1. Install: Bush 1 Thrust bearing 2 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: Collar 1 To relay arm 2. NOTE: Apply the molybdenum disulfide grease on the collars, bearings and oil seal lips.
Page 473 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE IC5751B2 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 474 CHAS SWINGARM 5. Install: Relay arm 1 Bolt (relay arm) 2 Plain washer 3 Nut (relay arm) 4 To swingarm. NOTE: Apply the molybdenum disulfide grease on the bolt. Do not tighten the nut yet. 6. Install: Swingarm 1 Pivot shaft 2 85 Nm (8.5 m•kg, 61 ft•lb) NOTE: Apply the molybdenum disulfide grease on the...
Page 475 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 Rosetta 3 9 Beilegescheibe 3...
Page 476 CHAS SWINGARM 10. Tighten: Nut (connecting rod) 1 80 Nm (8.0 m•kg, 58 ft•lb) 11. Tighten: Nut (relay arm) 1 80 Nm (8.0 m•kg, 58 ft•lb) 12. Install: Cap 1 NOTE: Install the cap (right) with its mark a facing for- ward.
Page 477 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 478 CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER 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...
Page 479 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 480 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 481 IC587000 REMARQUE CONCER- NOTE SULLO SMALTI- NANT LA MISEAU REBUT VERSCHROTTUNGSANLEI- MENTO (SOLTANTO CON- DE L’AMORTISSEUR TUNG (NUR FÜR YAMAHA CESSIONARI YAMAHA) Prima di smaltire l’ammortizzatore, as- (TRAVAIL A EFFECTUER FACHHÄNDLER) sicurarsi di estrarre l’azoto gassoso dal- Verschrotten CHEZ UN CONCESSION- la valvola 1.
Page 482 CHAS REAR SHOCK ABSORBER EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3.
Page 483 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 HINWEIS:...
Page 484 CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585320 Bearing 1. Install: Upper 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 485 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 Roulement supérieur 1 9 Oben Lager 1 9 Cuscinetto superiore 1 HINWEIS: N.B.: NOTA: Das Lager am äußeren Laufring paral-...
Page 486 CHAS REAR SHOCK ABSORBER 3. Adjust: Spring length (installed) a Spring length (installed) a a : Standard Extent of length adjustment 248 mm (9.76 in) 240.5~258.5 mm (9.47~10.18 in) *262 mm (10.31 in) *255.5~273.5 mm (10.06~10.77 in) *For EUROPE NOTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster.
Page 487 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: Lunghezza della molla (monté)a: (installata)a: Standard-.
Page 488 CHAS REAR SHOCK ABSORBER 3. Install: Rear shock absorber 4. Install: Bolt (rear shock absorber-frame) 1 Nut (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: Bolt (rear shock absorber-relay arm) 1 Nut (rear shock absorber-relay arm) 2 53 Nm (5.3 m•kg, 38 ft•lb) NOTE:...
Page 489 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 490 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 491 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 ELETTRICO ELEKTRISCHE BAUTEILE 1 Bouton d’arrêt du moteur “ENGINE...
Page 492 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 493 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 494 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 495 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 496 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. Spark plug cap 3 Spark plug 4 A For USA and CDN B Except for USA and CDN ∫...
Page 497 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 498 ELEC IGNITION SYSTEM EC626002 IGNITION COIL INSPECTION 1. Inspect: Primary coil resistance Out of specification ¡ Replace. Tester (+) lead ¡ Orange lead 1 Tester (–) lead ¡ Black lead 2 Primary coil Tester selector resistance position 0.14~0.20Ω at Ω × 1 20°C (68°F) 2.
Page 499 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 ¡...
Page 500 ELEC IGNITION SYSTEM EC627011 CDI MAGNETO INSPECTION 1. Inspect: Pick-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 248~372Ω at Ω × 100 20°C (68°F) 2.
Page 501 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 Fuori specifica ¡...
Page 502 SETTING EC700000 TUNING EC710000 ENGINE EC711001 Carburetor setting The 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 503 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 504 SETTING That is: Higher temperature expands the air with its resultant reduced density. Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air. Lower atmospheric pressure (at a high altitude) reduces the density of the air.
Page 505 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 506 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 507 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 Pièce de réglage Fermé...
Page 508 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 509 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 510 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 511 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 512 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. 6CHY5-78 6CHY5-79 1.
Page 513 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 6CHY5-78 de l’aiguille.
Page 514 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- 6CHY5-78 seln der Düsennadel. 6CHY5-79 6CHY5-80 1.
Page 515 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 6CHY5-78 richiede il cambiamento dell’ago a getto. 6CHY5-79 6CHY5-80 1.
Page 516 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. 6CHY5-76 6CHY5-77 1. The jet needle setting parts, having the same 6CHY5-78 taper angle, are available in different straight portion diameters and in different taper start-...
Page 517 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 6CHY5-76 de l’aiguille. 6CHY5-77 6CHY5-78 1.
Page 518 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- 6CHY5-76 seln der Düsennadel. 6CHY5-77 6CHY5-78 1. Die Düsennadel-Einstellteile mit dem glei- chen Konuswinkel sind in Ausführungen mit unterschiedlichen Durchmessern des gera- den Teils und mit unterschiedlichen Konus-...
Page 519 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 6CHY5-76 richiede il cambiamento dell’ago a getto. 6CHY5-77 6CHY5-78 1.
Page 520 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 521 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 522 SETTING EC71Q000 Carburetor setting parts Part name Size Part number Main jet Lean #390 137-14143-78 #400 137-14143-80 #410 137-14143-82 (STD) #420 137-14143-84 *(STD) #430 137-14143-86 #440 137-14143-88 #450 137-14143-90 Rich #460 137-14143-92 Pilot jet 2 2 Lean 4KM-14142-20 #22.5 4KM-14142-22 4KM-14142-25 #27.5 4KM-14142-27...
Page 523 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 #390 137-14143-78 Gicleur Pauvre #390 137-14143-78 düse Getto Povera No.
Page 524 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) #430 #420 #410 #450...
Page 525 SETTING Symptom Setting Checking Number of turns-back ¡ 0~1/4 throttle Use jet needle having a smaller *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 526 REGLAGE Conditions de la route et exemples de réglages de carburateur Conditions Générales Sablonneux Moins Plus de 30°C Moins de Plus de 30°C 15 à 25°C 15 à 25°C de 10°C (50°F) (59 à 77°F) (86°F) 10°C (50°F) (59 à 77°F) (86°F) Pièce (Hiver)
Page 527 REGLAGE Réglages Contrôler Symptômes Nombre de tours de dévissage ¡ 0~1/4 de papillon Utiliser une aiguille de gicleur avec un diamètre inférieur. Corriger correctement *Attaque difficile Fuite en provenance du carburateur Perte de vitesse 0~1/4 de papillon Utiliser une aiguille de gicleur avec un Mauvaise accélération diamètre supérieur.
Page 528 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) (Frühling, Herbst) (Sommer) (Winter) (Frühling, Herbst) (Sommer) #430 #420 #410 #450 #440 #430 Hauptdüse *#440...
Page 529 EINSTELLUNG Symptom Einstellung Prüfung Anzahl der Ausdrehungen ¡ 0~1/4 Gas Eine Düsennadel mit kleinerem * 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 530 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 531 REGISTRAZIONE Sintomo Registrazione Controllo Numero di giri in senso contrario ¡ Valvola a farfalla a 0 ~ 1/4 Usare un ago a getto che abbia un *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 532 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 533 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 534 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 49/13 (3.769) reduction ratio <Requirement for selection of secondary gear reduction ratio> It 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 535 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 536 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 5NY-25448-00 (STD) 5NY-25449-00 5NY-25450-00 5NY-25451-00 5NY-25452-00 EC721003 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit.
Page 537 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 538 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 Change the fork oil level.
Page 539 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- sazione che il guidatore ha di una corsa que des conditions du terrain.
Page 540 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 541 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 542 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: Change the rebound damping.
Page 543 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 544 SETTING EC72P010 Front fork setting parts Adjustment washer 1 TYPE (thickness) PART NUMBER T=2.3 mm (0.09 in) 4SS-23364-L0 Front fork spring 2 [Equal pitch spring ] I.D. SPRING SPRING TYPE MARK RATE PART NUMBER (slits) 0.380 4SS-23141-10 SOFT 0.390 4SS-23141-20 I-II 0.400 4SS-23141-30...
Page 545 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 546 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 Change the set length of the spring.
Page 547 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 548 SETTING NOTE: If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re-evaluation. If 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 549 REGLAGE EINSTELLUNG REGISTRAZIONE N.B.: NOTA: HINWEIS: 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 550 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: 490.5 mm (19.31 in) å...
Page 551 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- posteriore diverso da quello attual- teren Stoßdämpfers 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 552 SETTING EC72Q011 Rear shock absorber setting parts Rear shock spring 1 [Equal pitch spring ] I.D. SPRING SPRING SPRING TYPE COLOR FREE RATE PART NUMBER /POINT LENGTH 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 553 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 554 SETTING EC72H010 Suspension setting Front fork NOTE: If 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. Before any change, set the rear shock absorber sunken length to the standard figure 90~100 mm (3.5~3.9 in).
Page 555 SETTING Rear shock absorber NOTE: If 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. Adjust the rebound damping in 2-click increments or decrements. Adjust the low compression damping in 1-click increments or decrements.
Page 556 REGLAGE Réglage de la suspension 9 Fourche avant N.B.: Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effec- tur un nouveau réglage en se référant aux procédés repris dans ce tableau. Avant d’effectuer toute modification, régler la longueur enfoncée de l’amortisseur arrière à la valeur stan- dard de 90~100 mm (3,5~3,9 in).
Page 557 REGLAGE 9 Amortisseur arrière N.B.: Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, ettec- tur un nouveau réglage en se référant aux procédés repris dans ce tableau. Ajuster la force de rebond par incréments et décréments de 2 déclics. Ajuster la force d’amortissement de compression basse par incréments ou décréments de 1 déclic.
Page 558 EINSTELLUNG Federungseinstellung 9 Vorderradgabel HINWEIS: 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 559 EINSTELLUNG 9 Hinterradstoßdämpfer HINWEIS: 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 560 REGISTRAZIONE IC72H010 Registrazione della sospensione 9 Forcella anteriore NOTA: 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. Prima di qualsiasi modifica, registrare la lunghezza abbassata dell’ammortizzatore posteriore sulla cifra normale di 90~100 mm (3,5~3,9 in).
Page 561 REGISTRAZIONE • Ammortizzatore posteriore NOTA: 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. Regolare lo smorzamento dell’estensione in incrementi o decrementi di 2 scatti. Regolare lo smorzamento a bassa compressione in incrementi o decrementi di 1 scatto.
Page 562 MEMO...
Page 564 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2001.5—2.8 × 1 ! PRINTED ON RECYCLED PAPER (E, F, G, H)

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Yz125p/lc 2001

Yamaha YZ125/LC 2001 Manuel D'atelier Du Proprietaire

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