Page 1 All manuals and user guides at all-guides.com OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU ET PROPRIETAIRE FAHRER- UND WARTUNGS-HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO WR250F 5PH-28199-30...
Page 2 All manuals and user guides at all-guides.com EC010010 WR250F(N) OWNER’S SERVICE MANUAL ©2000 by Yamaha Motor Co., Ltd. 1st Edition, November 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 3 HANDBUCH PROPRIETARIO © © 2000 Yamaha Motor Co., Ltd. 2000 Yamaha Motor Co., Ltd. ©2000 by Yamaha Motor Co., Ltd. 1ère édition, novembre 2000 1. Auflage, November 2000 edizione, novembre 2000 Tous droits réservés Alle Rechte vorbehalten. Tutti i diritti sono riservati.
Page 4 All manuals and user guides at all-guides.com EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
Page 5 Daraus resultiert ein hohes plus élevé de la dextérité manuelle et de massimo grado di quella eccezionalità la fiabilité qui ont fait de Yamaha un lea- Maß an Qualität und die sprichwörtli- qualitativa e affidabilità che hanno reso der.
Page 6 All manuals and user guides at all-guides.com IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal.
Page 7 All manuals and user guides at all-guides.com ZUR BEACHTUNG NOTICE COMUNICAZIONE IMPORTANTE IMPORTANTE Dieses Motorrad ist ausschließlich für den Einsatz im Gelände-Renn- CETTE MACHINE EST STRICTE- QUESTO VEICOLO È STATO PRO- sport auf geschlossenen Kursen MENT DESTINEE A LA COMPETI- GETTATO ESCLUSIVAMENTE PER bestimmt.
Page 8 All manuals and user guides at all-guides.com 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.
Page 9 All manuals and user guides at all-guides.com 6. Benzin ist giftig. L’ESSENCE PEUT CAUSER LA BENZINA PUÒ PROVO- Sollten Sie versehentlich DES BLESSURES. CARE DANNI PERSONALI. Si vous avalez de l’essence, res- Benzin verschluckt, Ben- In caso di ingestione involonta- pirez des vapeurs d’essence en zindämpfe eingeatmet oder ria di benzina, inalazione...
Page 10 If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold.
Page 11 Sie sich ou l’entretien de votre machine, veuillez del veicolo, consultare il proprio rivendi- vor Unfällen schützen. consulter votre concessionnaire Yamaha. tore Yamaha. Wenn Sie die vielen Tips der Bedie- N.B.: nungsanleitung nutzen, garantieren NOTA: Ce manuel doit être considéré...
Page 12 All manuals and user guides at all-guides.com EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
Page 13 All manuals and user guides at all-guides.com BENUTZERHINWEISE COMMENT UTILISER COME UTILIZZARE CE MANUEL QUESTO MANUALE INFORMATIONS PARTI- KENNZEICHNUNG WICH- INFORMAZIONI PARTI- TIGER HINWEISE CULIEREMENT IMPOR- COLARMENTE IMPOR- TANTES TANTI Questo simbolo segnala un pericolo che Ausrufezeichen bedeutet: Le symbole d’alerte de sécurité signifie richiede la MASSIMA ATTENZIONE! “GEFAHR! Achten Sie auf Ihre ATTENTION! SOYEZ VIGILANT!
Page 14 All manuals and user guides at all-guides.com 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.
Page 15 All manuals and user guides at all-guides.com AUFBAU FORMAT DU MANUEL STRUTTURA DEL MANUALE Diese Anleitung wurde zusammen- Dans ce manuel, toutes les procédures gestellt, um dem Benutzer ein leicht sont décrites pas à pas. Les informations Tutte le procedure di questo manuale verständliches Nachschlagewerk in ont été...
Page 16 All manuals and user guides at all-guides.com ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC Illustrated symbols 1 to 7 are designed as INFO thumb tabs to indicate the chapter’s number and content. 1 General information INSP 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical...
Page 17 All manuals and user guides at all-guides.com ABGEBILDETEN SYM- SYMBOLES GRAPHI- SIMBOLI ILLUSTRATI QUES (Fare riferimento all’illu- (Siehe Abbildung) (Voir l’illustration) strazione) Die unter 1 bis 7 abgebildeten Les symboles graphiques 1 à 7 servent I simboli illustrati da 1 a 7 vengono Symbole weisen auf die Themen der à...
Page 18 All manuals and user guides at all-guides.com EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...
Page 19 All manuals and user guides at all-guides.com INDEX INDEX INDICE ALLGEMEINE RENSEIGNEMENTS- INFORMAZIONI GENERAUX GENERALI ANGABEN INFO TECHNISCHE CARACTERISTI- SPECIFICHE QUES DATEN SPEC REGELMÄSSIGE CONTROLES ET ISPEZIONI E INSPEKTION UND REGLAGES REGISTRAZIONI INSP COURANTS REGOLARI EINSTELLARBEITEN MOTOR MOTEUR MOTORE FAHRWERK PARTIE CYCLE PARTE CICLISTICA CHAS...
Page 20 All manuals and user guides at all-guides.com EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......... 1-1 MACHINE IDENTIFICATION ....1-2 IMPORTANT INFORMATION ....1-3 CHECKING OF CONNECTION ....1-6 SPECIAL TOOLS ........1-7 CONTROL FUNCTIONS ......1-10 FUEL ............1-13 STARTING AND BREAK-IN ....
Page 21 All manuals and user guides at all-guides.com INHALT TABLES DES INDICE MATIERES KAPITEL 1 CAPITOLO 1 CHAPITRE 1 ALLGEMEINE INFORMAZIONI ANGABEN RENSEIGNEMENTS GENERALI GENERAUX FAHRZEUGBESCHREIBUNG ...1-1 DESCRIZIONE .......1-1 FAHRZEUG- IDENTIFICAZIONE DEL DESCRIPTION .......1-1 IDENTIFIZIERUNG .....1-2 VEICOLO ........1-2 IDENTIFICATION DE WICHTIGE INFORMATIONEN ...1-3 INFORMAZIONI LA MACHINE ........1-2 ANSCHLÜSSE PRÜFEN ...1-6...
Page 22 All manuals and user guides at all-guides.com CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ......... 4-1 EXHAUST PIPE AND SILENCER .... 4-2 RADIATOR ..........4-4 CARBURETOR ......... 4-7 CAMSHAFTS .......... 4-20 CYLINDER HEAD ........4-29 VALVES AND VALVE SPRINGS ... 4-33 CYLINDER AND PISTON .......
Page 23 All manuals and user guides at all-guides.com KAPITEL 4 CHAPITRE 4 CAPITOLO 4 MOTEUR MOTOR MOTORE SITZBANK, SELLE, RESERVOIR DE SELLA, SERBATOIO CARBURANT ET CACHES KRAFTSTOFFTANK UND CARBURANTE E LATERAUX ........4-1 SEITENABDECKUNGEN ...4-1 CARENATURA LATERALE ..4-1 TUYAU D’ECHAPPEMENT KRÜMMER UND TUBO DI SCARICO ET SILENCIEUX ......4-2 SCHALLDÄMPFER ....4-2...
Page 24 All manuals and user guides at all-guides.com CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ......6-1 MAP-CONTROLLED CDI UNIT ....6-2 IGNITION SYSTEM ........6-3 THROTTLE POSITION SENSOR SYSTEM ........6-7 LIGHTING SYSTEM ....... 6-11 CHAPTER 7 TUNING ENGINE ............. 7-1 CHASSIS ..........
Page 25 All manuals and user guides at all-guides.com KAPITEL 6 CHAPITRE 6 CAPITOLO 6 PARTIE ELEKTRISCHE IMPIANTO ANLAGE ELECTRIQUE ELETTRICO COMPOSANTS ELECTRIQUES ELEKTRISCHE BAUTEILE COMPONENTI ELETTRICI E ET SCHEMA DE CABLAGE ..6-1 UND SCHALTPLAN ....6-1 SCHEMA DI CABLAGGIO ..6-1 BLOC CDI CONTROLE PAR KENNFELDGESTEUERTES UNITÀ...
Page 26 All manuals and user guides at all-guides.com DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever NOTE: 2 Decompression lever The machine you have purchased may differ 3 Trip meter slightly from those shown in the following. 4 Light switch Designs and specifications are subject to 5 Front brake lever change without notice.
Page 27 All manuals and user guides at all-guides.com DESCRIPTION FAHRZEUGBESCHREIBUNG DESCRIZIONE INFO ALLGEMEINE RENSEIGNEMENTS INFORMAZIONI ANGABEN GENERAUX GENERALI DESCRIPTION FAHRZEUGBESCHREI- DESCRIZIONE BUNG 1 Levier d’embrayage 1 Leva della frizione 2 Levier de décompression 2 Leva della decompressione 1 Kupplungshebel 3 Compteur de vitesse 3 Contachilometri parziale 2 Dekompressionshebel 4 Contacteur d’éclairage...
Page 28 There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for posi- tive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
Page 29 2. bei einer Diebstahlmeldung concessionnaire Yamaha numero al proprio rivenditore d’identifier clairement la machine. Yamaha per identificare corretta- En cas de vol du véhicule, la mente il modello. police réclamera ces numéros Se il veicolo viene rubato, le afin de faciliter son identification.
Page 30 All manuals and user guides at all-guides.com IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassem- bly. When washing the machine with high pressured water, cover the parts follows. Silencer end Air filter intake hole Water pump housing hole at the bottom...
Page 31 All manuals and user guides at all-guides.com INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO WICHTIGE INFORMATIO- INFORMATIONS IMPOR- INFORMAZIONI IMPOR- TANTES TANTI VORBEREITUNG FÜR AUSBAU PREPARATION POUR LA DEPOSE PREPARATIVI PER LA RIMO- UND ZERLEGUNG ET DEMONTAGE ZIONE E IL DISASSEMBLAGGIO 1.
Page 32 All manuals and user guides at all-guides.com IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1.
Page 33 Yamaha lors des esclusivamente oli e/o grassi con- gestellten Qualitätsanforde- remontages et réglages. sigliati da Yamaha per il montag- rungen. gio e le regolazioni. JOINTS, BAGUES D’ETANCHEITE DICHTUNGEN, DICHTRINGE UND GUARNIZIONI, PARAOLIO E O-...
Page 34 All manuals and user guides at all-guides.com IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlip 1, make sure that the sharp-edged cor- ner 2 is positioned opposite to the thrust 3 it receives.
Page 35 All manuals and user guides at all-guides.com INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO SICHERUNGSRINGE CIRCLIPS ANELLI ELASTICI DI ARRESTO 1. Sicherungsringe vor dem Wie- Avant remontage, tous les circlips Ispezionare attentamente tutti gli dereinbau sorgfältig überprü- doivent être soigneusement véri- anelli elastici di arresto prima di fen und bei Beschädigung fiés.
Page 36 All manuals and user guides at all-guides.com 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.
Page 37 All manuals and user guides at all-guides.com VERIFICATION DES CONNEXIONS ANSCHLÜSSE PRÜFEN CONTROLLO DEI COLLEGAMENTI INFO ANSCHLÜSSE PRÜFEN VERIFICATION DES CONTROLLO DEI COL- Die Steckverbinder auf Oxidation, CONNEXIONS LEGAMENTI Rost, Feuchtigkeit usw. prüfen Traitement des taches, de la rouille, de Come gestire macchie, ruggine, umidità, 1.
Page 38 All manuals and user guides at all-guides.com SPECIAL TOOLS INFO EC140001 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.
Page 39 All manuals and user guides at all-guides.com SPECIAL TOOLS INFO Part number Tool name/How to use Illustration YU-33975, 90890-01403 Steering nut wrench YU-33975 90890-01403 This tool is used when tighten the steering ring nut to specification. YM-1423, 90890-01423 Damper rod holder YM-1423 90890-01423 Use this tool to remove and install the damper rod.
Page 40 Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. ® ACC-QUICK-GS-KT Quick gasket ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc. 1 - 9...
Page 41 All manuals and user guides at all-guides.com 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.
Page 42 All manuals and user guides at all-guides.com OUTILS SPECIAUX INFO Numéros de pièce Nom et usage de l’outil Illustration YU-33975, 90890-01403 Clé à ergots YU-33975 90890-01403 Cet outil est utilisé pour serrer l’écrou crénelé de direction aux spécifications. YM-1423, 90890-01423 Poignée de tige d’amortisseur YM-1423 90890-01423...
Page 43 90890-06754 Contrôleur d’allumage. Ce testeur est nécessaire pour contrôler les composants du système d’allumage. ® ACC-QUICK-GS-KT Quick gasket ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond n˚ 1215 Ce mastic est utilisé sur les plans de joint du carter, etc. 1 - 9...
Page 44 All manuals and user guides at all-guides.com SPEZIALWERKZEUGE INFO SPEZIALWERKZEUGE Die folgenden Spezialwerkzeuge sind für korrekte und vollständige Einstell- und Montagearbeiten unerläßlich. Durch die Verwendung dieser Werkzeuge können Beschädigungen vermieden wer- den, die beim Gebrauch ungeeigneter Hilfsmittel oder improvisierter Techniken entstehen können. Bei der Bestellung von Spezialwerkzeug sollten die im folgenden aufgeführten Bezeichnungen und Teilenummern angegeben werden.
Page 45 All manuals and user guides at all-guides.com SPEZIALWERKZEUGE INFO Teilenummer Werkzeug/Anwendung Abbildung YU-33975, 90890-01403 Hakenschlüssel YU-33975 90890-01403 Zum Lösen und Festziehen der Lenkkopf-Ringmut- ter. YM-1423, 90890-01423 Dämpferrohr-Halter YM-1423 90890-01423 Zum Lösen und Festziehen der Befestigungs- schraube des Teleskopgabel-Dämpferrohrs. YM-01442, 90890-01442 Gabeldichtring-Treiber YM-01442 90890-01442...
Page 46 YM-4118, 90890-04118 Einlaß 4,0 mm Auslaß 4,5 mm Zum Aufreiben der neuen Ventilführungen. YM-34487 Zündfunkenstreckentester YM-34487 90890-06754 90890-06754 Zündprüfer Zur Überprüfung der Zündanlage. ® ACC-QUICK-GS-KT Quick gasket ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA-Dichtmasse Nr. 1215 Zum Abdichten der Kurbelgehäuse-Paßflächen. 1 - 9...
Page 47 All manuals and user guides at all-guides.com UTENSILI SPECIALI INFO UTENSILI SPECIALI Sono necessari idonei utensili speciali per una messa a punto e un assemblaggio completi e accurati. L’impiego dell’attrezzo speciale adatto aiuterà a prevenire eventuali danni causati dall’impiego di utensili non idonei o di tecniche improvvisate.
Page 48 All manuals and user guides at all-guides.com UTENSILI SPECIALI INFO Numero di pezzo Nome dell’attrezzo/Come utilizzarlo Figura YU-33975, 90890-01403 Chiave per ghiere YU-33975 90890-01403 Questo attrezzo è utilizzato per serrare le ghiere fino ai valori indicati nelle specifiche. YM-1423, 90890-01423 Utensile di blocco dell’asta ammortizzatore YM-1423 90890-01423...
Page 49 Questo attrezzo è necessario per il controllo dei componenti del sistema di accensione. ® ACC-QUICK-GS-KT Quick gasket ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond n. 1215 Questo materiale di tenuta (agglomerante) è utilizzato per chiudere ermeticamente due superfici di contatto, ecc. 1 - 9...
Page 50 All manuals and user guides at all-guides.com CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han-...
Page 51 All manuals and user guides at all-guides.com FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION FUNZIONI DI COMANDO INFO ARMATUREN UND DE- FONCTIONS DES COM- FUNZIONI DI COMANDO REN FUNKTION MANDES INTERRUTTORE ARRESTO DEL MOTORE MOTORSTOPPSCHALTER COUPE-CIRCUIT DU MOTEUR L’interruttore di arresto del motore 1 è Der Motorstoppschalter 1 befindet Le coupe-circuit du moteur 1 est situé...
Page 52 All manuals and user guides at all-guides.com CONTROL FUNCTIONS INFO DECOMPRESSION LEVER CAUTION: Never use the decompression lever after the engine is started. The engine may be damaged if you use the decompression lever while it is running. The decompression lever 1 is located on the left handlebar and is used when starting the engine.
Page 53 All manuals and user guides at all-guides.com FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION FUNZIONI DI COMANDO INFO DEKOMPRESSIONSHEBEL LEVIER DE DECOMPRESSION LEVA DI DECOMPRESSIONE ATTENZIONE: ATTENTION: ACHTUNG: Ne jamais employer le levier de Den Dekompressionshebel unter Non utilizzare mai la leva di decom- décompression une fois que le moteur keinen Umständen bei laufendem pressione dopo aver avviato il motore.
Page 54 All manuals and user guides at all-guides.com CONTROL FUNCTIONS INFO EC158010 FUEL COCK The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the three positions: OFF:With the lever in this position, fuel will not flow.
Page 55 All manuals and user guides at all-guides.com FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION FUNZIONI DI COMANDO INFO KRAFTSTOFFHAHN ROBINET DE CARBURANT RUBINETTO DEL CARBURANTE Der Kraftstoffhahn regelt die Kraft- Le robinet de carburant fournit le carbu- Il rubinetto del carburante alimenta il stoffzufuhr vom Tank zum Vergaser rant du réservoir au carburateur et la fil- carburante dal serbatoio al carburatore...
Page 56 All manuals and user guides at all-guides.com CONTROL FUNCTIONS/FUEL INFO EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward. LIGHTS SWITCH The lights switch 1 is located on the handle- bar.
Page 57 All manuals and user guides at all-guides.com FONCTIONS DES COMMANDES/ESSENCE ARMATUREN UND DEREN FUNKTION/KRAFTSTOFF FUNZIONI DI COMANDO/CARBURANTE INFO AUSLAUFSCHUTZVENTIL CLAPET DE DURIT DE MISE A GIUNTO A VALVOLA Das Auslaufschutzventil 1 ist in den Questo giunto a valvola 1 impedisce la LIAIR Ce clapet 1 évite que l’essence ne Kraft–stofftank-Belüftungsschlauch...
Page 58 All manuals and user guides at all-guides.com STARTING AND BREAK-IN INFO STARTING AND BREAK-IN WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area.
Page 59 All manuals and user guides at all-guides.com MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO ANLASSEN UND EINFAH- MISE EN MARCHE ET AVVIO E RODAGGIO RODAGE AVVERTENZA WARNUNG AVERTISSEMENT Non avviare mai né tenere in funzione il motore in un’area chiusa.
Page 60 All manuals and user guides at all-guides.com STARTING AND BREAK-IN INFO 6. Pull the decompression lever to the han- dlebar and depress the kickstarter crank 10 ~ 20˚. 7. Release the decompression lever and return the kickstarter crank to its original position and then kick the kickstarter crank.
Page 61 All manuals and user guides at all-guides.com MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO 6. Den Dekompressionshebel Actionner à fond le levier de Tirare la leva di decompressione anziehen und den Kickstarter- décompression et actionner le verso il manubrio e premere la hebel um 10–20˚...
Page 62 All manuals and user guides at all-guides.com STARTING AND BREAK-IN INFO STARTING A WARM ENGINE Do not operate the cold starter knob and throt- tle. Open the hot starter knob (red) and start the engine by kicking the kickstarter crank forcefully with a firm stroke.
Page 63 All manuals and user guides at all-guides.com MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO STARTEN MIT WARMEM MOTOR MISE MARCHE D’UN AVVIAMENTO DI UN MOTORE Zum Anlassen des warmen Motors MOTEUR CHAUD CALDO weder den Kaltstarterknopf drücken Ne pas activer le bouton de démarrage a Non agire sulla manopola di avviamento noch den Gasdrehgriff öffnen, son-...
Page 64 All manuals and user guides at all-guides.com STARTING AND BREAK-IN INFO BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch.
Page 65 All manuals and user guides at all-guides.com MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO EINFAHRVORSCHRIFTEN PROCEDURE DE RODAGE PROCEDURE DI RODAGGIO 1. Vor dem Anlassen des Motors Avant de mettre le moteur en Prima di avviare il motore, riem- volltanken.
Page 66 All manuals and user guides at all-guides.com TORQUE-CHECK POINTS INFO TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Steering Steering stem to Steering stem to frame Steering stem to upper bracket handlebar...
Page 67 All manuals and user guides at all-guides.com POINTS DE VERIFICATION DE COUPLE DE SERRAGE INFO POINTS DE VERIFICATION DE COUPLE DE SERRAGE Construction du cadre Cadre et cadre arrière Fixation entre selle Réservoir de carburant et cadre et réservoir Système d’échappement Silencieux et cadre arrière Montage du moteur Cadre et moteur...
Page 68 All manuals and user guides at all-guides.com ANZUGSMOMENTE KONTROLLIEREN INFO ANZUGSMOMENTE KONTROLLIEREN Rahmen Hauptrahmen und Rahmenhinterteil Sitzbank und Kraftstofftank Kraftstofftank und Rahmen Auspuff-System Schalldämpfer an Hinterrahmen Motoraufhängung Rahmen und Motor Lenkung Lenkkopf bis Lenkkopf und Teleskopgabel Lenkkopf und obere Gabelbrücke Lenker obere Gabelbrücke und Lenker Radaufhängung...
Page 69 All manuals and user guides at all-guides.com PUNTI PER IL CONTROLLO DEL SERRAGGIO INFO PUNTI PER IL CONTROLLO DEL SERRAGGIO Struttura del telaio Telaio al telaio posteriore Sella e serbatoio del Serbatoio del carburante al telaio carburante combinati Sistema di scarico Marmitta di scarico al telaio posteriore Supporto motore Telaio al motore...
Page 70 All manuals and user guides at all-guides.com CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good over- all performance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.
Page 71 All manuals and user guides at all-guides.com NETTOYAGE ET RANGEMENT REINIGUNG UND STILLEGUNG PULIZIA ED IMMAGAZZINAGGIO INFO REINIGUNG UND STILLE- NETTOYAGE ET RANGE- PULIZIA ED IMMAGAZ- GUNG MENT ZINAGGIO REINIGUNG NETTOYAGE PULIZIA Eine regelmäßige, gründliche Un nettoyage fréquent de la machine Una pulizia frequente del veicolo ne Wäsche sorgt nicht nur für gutes améliorera son aspect, maintiendra ses...
Page 72 All manuals and user guides at all-guides.com CLEANING AND STORAGE INFO EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1.
Page 73 All manuals and user guides at all-guides.com NETTOYAGE ET RANGEMENT REINIGUNG UND STILLEGUNG PULIZIA ED IMMAGAZZINAGGIO INFO STILLEGUNG RANGEMENT IMMAGAZZINAGGIO Vor einer mehr als zweimonatigen Si l’on remise la machine pour 60 jours Se il veicolo va immagazzinato 60 giorni Stillegung sollten einige Schutzvor- ou plus, il faut prendre des mesures de o oltre, è...
Page 74 SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: WR250FN (USA) WR250F (EUROPE) WR250F(N) (CDN, AUS, NZ, ZA) Model code number: 5PH1 (USA) 5PH2 (EUROPE) 5PH4 (CDN, AUS, NZ, ZA) Dimensions: Overall length 2,165 mm (85.2 in) Overall width 827 mm (32.6 in)
Page 75 All manuals and user guides at all-guides.com SPEC GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 1.5 L (1.32 Imp qt, 1.59 US qt) With oil filter replacement 1.6 L (1.41 Imp qt, 1.69 US qt) Total amount 1.7 L (1.50 Imp qt, 1.80 US qt) Coolant capacity (including all routes): 1.3 L (1.14 Imp qt, 1.37 US qt) Air filter:...
Page 76 All manuals and user guides at all-guides.com SPEC GENERAL SPECIFICATIONS Tire: Type With tube Size (front) 80/100-21 51M (For USA, CDN and ZA) 90/90-21 54R (For EUROPE, AUS and NZ) Size (rear) 100/100-18 59M (For USA, CDN and ZA) 120/90-18 65R (For EUROPE, AUS and NZ) Tire pressure (front and rear) 100 kPa (1.0 kg/cm , 15 psi)
Page 77 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 77.00 ~ 77.01 mm ---- (3.0315 ~ 3.0319 in) Out of round limit ---- 0.05 mm (0.002 in)
Page 78 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 92RH2010-114M/114 ---- Timing chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.10 ~ 0.15 mm ---- (0.0039 ~ 0.0059 in) 0.17 ~ 0.22 mm...
Page 79 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in)
Page 80 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston pin bore inside diameter 16.002 ~ 16.013 mm 16.043 mm (0.6300 ~ 0.6304 in) (0.6316 in) Piston pin outside diameter 15.991 ~ 16.000 mm 15.971 mm (0.6296 ~ 0.6299 in) (0.6288 in) Piston rings:...
Page 81 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness 2.9 ~ 3.1 mm 2.7 mm (0.114 ~ 0.122 in) (0.106 in) Quantity ---- Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- Quantity ----...
Page 82 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Wire mesh type ---- Oil pump type Trochoid type ---- Tip clearance 0.12 mm or less 0.20 mm (0.0047 in or less) (0.008 in) Side clearance 0.09 ~ 0.17 mm...
Page 83 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M10S × 1.0 Spark plug M6 × 1.0 Camshaft cap M12 × 1.0 Cylinder head blind plug screw M6 × 1.0 Cylinder head (stud bolt) M8 ×...
Page 84 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Silencer M8 × 1.25 Silencer clamp M6 × 1.0 Spark arrester (for USA) M6 × 1.0 Silencer end pipe (for USA) M6 ×...
Page 85 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN EUROPE AUS, NZ, ZA 300 mm (11.8 in) ← ← Front fork travel 460 mm (18.1 in) ←...
Page 86 All manuals and user guides at all-guides.com 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 ---- 18 × 1.85/Aluminum Rear rim size/material ---- Rim runout limit: Radial ----...
Page 87 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Upper bracket and outer tube M8 × 1.25 Lower bracket and outer tube M24 × 1.0 Upper bracket and steering stem 14.5 M8 ×...
Page 88 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M6 × 1.0 Rear brake disc M8 × 1.25 Brake pedal M6 × 1.0 Rear brake master cylinder M6 × 1.0 Rear brake reservoir tank M4 ×...
Page 89 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M6 × 1.0 Headlight stay (lower) and lower bracket M6 × 1.0 Headlight (left and right) M6 × 1.0 Headlight (lower) M6 ×...
Page 90 Limit Ignition system: Advancer type Electrical ---- CDI: Magneto-model/manufacturer F5NG 00/YAMAHA ---- 640 ~ 960 Ω at 20 ˚C (68 ˚F) Charging coil 1 resistance (color) ---- (Green – Brown) 464 ~ 696 Ω at 20 ˚C (68 ˚F) Charging coil 2 resistance (color) ---- (Green –...
Page 91 All manuals and user guides at all-guides.com GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book.
Page 92 SPEC CARACTERISTIQUES GENERALES CARACTERISTIQUES CARACTERISTIQUES GENERALES Nom de modèle: WR250FN (USA) WR250F (EUROPE) WR250F(N) (CDN, AUS, NZ, ZA) Numéro de code de modèle: 5PH1 (USA) 5PH2 (EUROPE) 5PH4 (CDN, AUS, NZ, ZA) Dimensions: Longueur hors tout 2.165 mm (85,2 in)
Page 93 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES GENERALES Quantité d’huile: Huile moteur Vidange périodique 1,5 L (1,32 Imp qt, 1,59 US qt) Avec remplacement du ﬁltre à huile 1,6 L (1,41 Imp qt, 1,69 US qt) Quantité totale 1,7 L (1,50 Imp qt, 1,80 US qt) Quantité...
Page 94 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES GENERALES Pneu: Type de pneu Avec chambre à air Taille de pneu (avant) 80/100-21 51M (USA, CDN et ZA) 90/90-21 54R (EUROPE, AUS et NZ) Taille de pneu (arrière) 100/100-18 59M (USA, CDN et ZA) 120/90-18 65R (EUROPE, AUS et NZ) Pression de pneu (avant et arrière) 100 kPa (1,0 kg/cm...
Page 95 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN CARACTERISTIQUES D’ENTRETIEN MOTEUR Article Standard Limite Culasse: Limite de déformation ---- 0,05 mm (0,002 in) Cylindre: Alésage 77,00 à 77,01 mm ---- (3,0315 à 3,0319 in) Limite d’ovalisation ---- 0,05 mm (0,002 in) Arbre à...
Page 96 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Chaîne de distribution: Type de chaîne de distribution/nbre de maillons 92RH2010-114M/114 ---- Méthode de réglage de la chaîne de distribution Automatique ---- Soupape, siège de soupape, guide de soupape: Jeu de soupape (à...
Page 97 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Limite de faux-rond de queue ---- 0,01 mm (0,0004 in) Largeur de siège de soupape 0,9 à 1,1 mm 1,6 mm (0,0354 à 0,0433 in) (0,0630 in) 0,9 à...
Page 98 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Décalage d’oriﬁce d’axe de piston 0,5 mm (0,020 in)/côté AD ---- Diamètre intérieur d’alésage d’axe de piston 16,002 à 16,013 mm 16,043 mm (0,6300 à 0,6304 in) (0,6316 in) Diamètre extérieur d’axe de piston 15,991 à...
Page 99 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Embrayage: Epaisseur de disque de friction 2,9 à 3,1 mm 2,7 mm (0,114 à 0,122 in) (0,106 in) Quantité ---- Epaisseur de disque d’embrayage 1,1 à 1,3 mm (0,043 à 0,051 in) ---- Quantité...
Page 100 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Système de graissage: Type de ﬁltre à huile A treillis métallique ---- Type de pompe à huile Trochoïde ---- Jeu en bout 0,12 mm ou moins 0,20 mm (0,0047 in ou moins) (0,008 in) Jeu latéral...
Page 101 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb M10S × 1,0 Bougie M6 × 1,0 Chapeau d’arbre à cames M12 × 1,0 Vis de plot borgne de culasse M6 ×...
Page 102 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb M8 × 1,25 Silencieux M8 × 1,25 Bride du silencieux M6 × 1,0 Pare-étincelles (pour les USA) M6 × 1,0 Chicane (pour les USA) M6 ×...
Page 103 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN PARTIE-CYCLE Article Standard Limite Direction: Type de roulement de direction Roulement à rouleaux conique ---- Suspension avant: USA, CDN EUROPE AUS, NZ, ZA ← ← Débattement de fourche avant 300 mm (11,8 in) ←...
Page 104 All manuals and user guides at all-guides.com 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 ---- 18 × 1,85/aluminum Taille/matériau de jante arrière ---- Limite de voile de jante:...
Page 105 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb M8 × 1,25 Té supérieur et fourreau M8 × 1,25 Té inférieur et fourreau M24 × 1,0 Té supérieur et colonne de direction 14,5 M8 ×...
Page 106 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb M6 × 1,0 Disque de frein arrière M8 × 1,25 Pédale de frein M6 × 1,0 Maître-cylindre de frein arrière M6 ×...
Page 107 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb M6 × 1,0 Support de phare (inférieur) et té inférieur M6 × 1,0 Phare (gauche et droite) M6 × 1,0 Phare (bas) M6 ×...
Page 108 Limite Système d’allumage: Type de dispositif d’avance Electrique ---- CDI: Modèle/fabricant de la magnéto F5NG 00/YAMAHA ---- 640 à 960 Ω à 20 ˚C (68 ˚F) Résistance de bobine de charge 1 ---- (couleur) (vert – brun) 464 à 696 Ω à 20 ˚C (68 ˚F) Résistance de bobines de charge 2...
Page 109 All manuals and user guides at all-guides.com CARACTERISTIQUES GENERALES DE COUPLE/ SPEC DEFINITION DES UNITES CARACTERISTIQUES GENERALES DE COUPLE Ce tableau spécifie les couples de serrage des atta- ches standard avec filetage à pas I.S.O. standard. Les spécifications de couple pour les composants ou ensembles spéciaux sont indiquées dans les sec- tions appropriées de ce manuel.
Page 110 All manuals and user guides at all-guides.com SPEC ALLGEMEINE TECHNISCHE DATEN TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN Modellname WR250F Modellcode 5PH2 Abmessungen Gesamtlänge 2.165 mm Gesamtbreite 827 mm Gesamthöhe 1.303 mm Sitzhöhe 998 mm Radstand 1.475 mm Bodenfreiheit 382 mm Fahrzeuggewicht (fahrfertig, vollgetankt)
Page 111 All manuals and user guides at all-guides.com SPEC ALLGEMEINE TECHNISCHE DATEN Füllmenge Ölwechsel ohne Filterwechsel 1,5 L Ölwechsel mit Filterwechsel 1,6 L Gesamtmenge 1,7 L Kühlsystem-Fassungsvermögen 1,3 L (Gesamtmenge) Luftﬁlter Naßfilter-Einsatz Kraftstoff Sorte Bleifreies Superbenzin mit einer Oktanzahl von mind. 95 Tankinhalt 8,0 L Reserve...
Page 112 All manuals and user guides at all-guides.com SPEC ALLGEMEINE TECHNISCHE DATEN Reifen Bauart Schlauchreifen Dimension vorn 90/90-21 54R hinten 120/90-18 65R Reifenluftdruck (vorn und hinten) 100 kPa (1,0 bar) Bremsanlage vorn Bauart Einscheibenbremse Betätigung Handbremshebel (rechts) hinten Bauart Einscheibenbremse Betätigung Fußbremshebel (rechts) Radaufhängung vorn...
Page 113 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN WARTUNGSDATEN MOTOR Bezeichnung Speziﬁkation Grenzwert Zylinderkopf Max. Verzug ---- 0,05 mm Zylinder Bohrungsdurchmesser 77,00–77,01 mm ---- Max. Ovalität ---- 0,05 mm Nockenwelle Antrieb Steuerkette (links) ---- Nockenwellenlager-Durchmesser 22,000–22,021 mm ---- Nockenwellen-Außendurchmesser 21,967–21,980 mm ---- Lagerspiel...
Page 114 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Steuerkette Typ/Gliederzahl 92RH2010-114M/114 ---- Kettenspannung automatisch ---- Ventile, Ventilsitze, Ventilführungen Ventilspiel (kalt) Einlaß 0,10–0,15 mm ---- Auslaß 0,17–0,22 mm ---- Ventilabmessungen Ventilsitzbreite Ventiltellerstärke Ventilkegelbreite Ventiltellerdurchmesser Ventilteller-Durchmesser Ventilteller-Breite Ventilsitz-Breite Ventilteller-Stärke Ventiltellerdurchmesser “A”...
Page 115 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Max. Ventilschaftschlag ---- 0,01 mm Ventilsitzbreite Einlaß 0,9–1,1 mm 1,6 mm Auslaß 0,9–1,1 mm 1,6 mm Ventilfeder Ungespannte Länge Einlaß 37,81 mm 35,9 mm Auslaß 37,54 mm 35,7 mm Einbaulänge (Ventil geschlossen) Einlaß...
Page 116 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Kolbenbolzenaugen-Durchmesser 16,002–16,013 mm 16,043 mm Kolbenbolzen-Durchmesser 15,991–16,000 mm 15,971 mm Kolbenringe 1. Kompressionsring (Topring) Ausführung abgerundet ---- Abmessungen (B × T) 0,90 × 2,75 mm ---- Stoßspiel (eingebaut) 0,15–0,25 mm 0,50 mm Ringnutspiel (eingebaut)
Page 117 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Kupplung Reibscheiben Stärke 2,9–3,1 mm 2,7 mm Anzahl ---- Kupplungsscheiben Stärke 1,1–1,3 mm ---- Anzahl ---- Verzug ---- 0,1 mm Kupplungsfeder ungesp. Länge 39,1 mm 38,1 mm Anzahl ---- Kupplungsgehäuse Axialspiel...
Page 118 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Schmiersystem Ölﬁlter Drahtgeﬂecht-Einsatz ---- Ölpumpe Rotorpumpe ---- Radialspiel 0,12 mm oder weniger 0,20 mm Axialspiel 0,09–0,17 mm 0,24 mm Gehäuse und Rotorabstand 0,03–0,10 mm 0,17 mm Kühlsystem Kühlerabmessungen Breite 117,8 mm ----...
Page 119 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Anzugs- moment Bauteil Gewinde Anz. m·kg M10S × 1,0 Zündkerze M6 × 1,0 Zündkerzenstecker M12 × 1,0 Zylinderkopf-Blindstopfenschraube M6 × 1,0 Zylinderkopf (Stiftschraube) M8 × 1,25 (Stiftschraube) M9 × 1,25 (Schraube) M6 ×...
Page 120 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Anzugs- moment Bauteil Gewinde Anz. m·kg M8 × 1,25 Schalldämpfer M8 × 1,25 Schalldämpfer-Schlauchschelle M6 × 1,0 Funkenfänger (für USA) M6 × 1,0 Schalldämpferendröhre (für USA) M6 × 1,0 Kurbelgehäuse M6 × 1,0 Kurbelkasten-Lageranschlag M6 ×...
Page 121 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN FAHRWERKL Bauteil Speziﬁkation Grenzwert Lenkung Lenkkopflager Kegelrollenlager ---- Federelement vorn Federweg 300 mm Gabelfeder, ungespannte Länge 460 mm Standard-Federrate K = 4,12 N/mm (0,42 kg/mm) Umrüstmöglichkeiten Ölmenge 578 cm Füllhöhe 130 mm <Min.–Max.>...
Page 122 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bauteil Speziﬁkation Grenzwert Räder Bauart: Vorderrad Speichenrad ---- Hinterrad Speichenrad ---- Felgendimension/-material ---- 21 × 1,60/Aluminium Vorderrad ---- 18 × 1,85/Aluminium Hinterrad ---- Max. Felgenschlag Höhenschlag ---- 2,0 mm Seitenschlag ---- 2,0 mm Antriebskette Typ (Hersteller)
Page 123 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg M8 × 1,25 Oberbügel und Außenröhre M8 × 1,25 Unterbügel und Außenröhre M24 × 1,0 Oberbügel und Lenkschaft 14,5 M8 × 1,25 Lenkerhalter und Oberbügel M28 × 1,0 Lenkschaft und Lenkringmutter Siehe HINWEIS.
Page 124 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg M6 × 1,0 Hinterradbremsscheibe M8 × 1,25 Bremspedal M6 × 1,0 Hinterradbrems-Hauptzylinder M6 × 1,0 Hinterradbrems-Ausgleichsbehälter M4 × 0,7 Hinterradbrems-Ausgleichsbehälterdeckel M10 × 1,25 Hinterradbremsschlauch-Verbindungsschraube M20 × 1,5 Hinterradachse und Achsmutter 12,5 Nippel (Speiche)
Page 125 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg M6 × 1,0 Scheinwerferstrebe (unten) und unterer Bügel M6 × 1,0 Scheinwerfer (links und rechts) M6 × 1,0 Scheinwerfer (unten) M6 × 1,0 Rückleuchte M4 × 1,59 Rückleuchtenleitungsklemme und hinteres Schutzblech M6 ×...
Page 126 Bauteil Speziﬁkation Grenzwert Zündsystem Zündversteller elektrisch ---- CDI-Schwungradmagnetzünder Typ (Hersteller) F5NG 00/YAMAHA ---- 640–960 Ω bei 20 ˚C Widerstand (Farbe) der Erregerspule 1 ---- (grün – braun) 464–696 Ω bei 20 ˚C Widerstand (Farbe) der Erregerspule 2 ---- (grün – rosa) 0,16–0,24 Ω...
Page 127 All manuals and user guides at all-guides.com ALLGEMEINE ANZUGSMOMENTE/ SPEC EINHEITEN ALLGEMEINE ANZUGSMOMENTE Aus der folgenden Tabelle sind die Anzugsmo- mente für normale Schraubverbindungen mit ISO-Normgewinde ersichtlich. Anzugsmomente für spezielle Verschraubungen und Bauteile wer- den in jedem Abschnitt dieser Anleitung geson- dert aufgeführt.
Page 128 All manuals and user guides at all-guides.com SPEC SPECIFICHE GENERALI SPECIFICHE SPECIFICHE GENERALI Nome del modello: WR250FN (USA) WR250F (EUROPA) WR250F(N) (CDN, AUS, NZ, ZA) Codice del modello: 5PH1 (USA) 5PH2 (EUROPA) 5PH4 (CDN, AUS, NZ, ZA) Dimensioni: Lunghezza totale 2.165 mm (85,2 in)
Page 129 All manuals and user guides at all-guides.com SPEC SPECIFICHE GENERALI Capacità olio: Olio motore Cambio d’olio periodico 1,5 L (1,32 Imp qt, 1,59 US qt) Con cambio filtro olio 1,6 L (1,41 Imp qt, 1,69 US qt) Quantità totale 1,7 L (1,50 Imp qt, 1,80 US qt) Capacità...
Page 130 All manuals and user guides at all-guides.com SPEC SPECIFICHE GENERALI Pneumatici: Tipo Con camera d’aria Dimensioni (anteriore) 80/100-21 51M (Per USA, CDN e ZA) 90/90-21 54R (Per l’EUROPA, AUS e NZ) Dimensioni (posteriore) 100/100-18 59M (Per USA, CDN e ZA) 120/90-18 65R (Per l’EUROPA, AUS e NZ) Pressione pneumatici (anteriore e posteriore) 100 kPa (1,0 kg/cm...
Page 131 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE SPECIFICHE DI MANUTENZIONE MOTORE Elemento Standard Limite Testata del cilindro: Limite di deformazione ---- 0,05 mm (0,002 in) Cilindro: Dimensioni alesaggio 77,00 ~ 77,01 mm ---- (3,0315 ~ 3,0319 in) Limite di ovalizzazione ---- 0,05 mm...
Page 132 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Catena di distribuzione: Tipo catena di distribuzione/N. di maglie 92RH2010-114M/114 ---- Metodo di regolazione della catena di Automatico ---- distribuzione Valvola, sede valvola, guidavalvola: Gioco valvola (a freddo) 0,10 ~ 0,15 mm ---- (0,0039 ~ 0,0059 in)
Page 133 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Limite disassamento stelo ---- 0,01 mm (0,0004 in) Larghezza sede valvola 0,9 ~ 1,1 mm 1,6 mm (0,0354 ~ 0,0433 in) (0,0630 in) 0,9 ~ 1,1 mm 1,6 mm (0,0354 ~ 0,0433 in) (0,0630 in)
Page 134 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Decentramento del pistone 0,5 mm (0,020 in)/lato INT ---- Diametro interno foro spinotto 16,002 ~ 16,013 mm 16,043 mm (0,6300 ~ 0,6304 in) (0,6316 in) Diametro esterno spinotto 15,991 ~ 16,000 mm 15,971 mm (0,6296 ~ 0,6299 in)
Page 135 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Frizione: Spessore del disco conduttore 2,9 ~ 3,1 mm 2,7 mm (0,114 ~ 0,122 in) (0,106 in) Quantità ---- Spessore del disco condotto 1,1 ~ 1,3 mm (0,043 ~ 0,051 in) ---- Quantità...
Page 136 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Sistema di lubrificazione: Tipo di filtro Tipo a maglia metallica ---- Tipo di pompa dell’olio Tipo trocoidale ---- Gioco della punta 0,12 mm o inferiore 0,20 mm (0,0047 in o inferiore) (0,008 in) Gioco laterale...
Page 137 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni Elemento da serrare Quantità della filettatura m·kg ft·lb M10S × 1,0 Candela d’accensione M6 × 1,0 Cappello dell’albero a camme M12 × 1,0 Tappo a vite testata del cilindro M6 ×...
Page 138 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni Elemento da serrare Quantità della filettatura m·kg ft·lb M8 × 1,25 Marmitta di scarico M8 × 1,25 Morsetto marmitta di scarico M6 × 1,0 Parascintille (per USA) M6 ×...
Page 139 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE PARTE CICLISTICA Elemento Standard Limite Sistema di sterzo: Tipo di cuscinetti sterzo Cuscinetto conico a rulli ---- Sospensione anteriore: USA, CDN EUROPE AUS, NZ, ZA ← ← Corsa forcella anteriore 300 mm (11,8 in) ←...
Page 140 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Ruota: Tipo ruota anteriore Ruota a raggi ---- Tipo ruota posteriore Ruota a raggi ---- 21 × 1,60/alluminio Dimensioni/materiale cerchio anteriore ---- Dimensioni/materiale cerchio posteriore 18 × 1,85/alluminio ---- Limite di disassamento cerchio: Radiale...
Page 141 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Dimensioni Coppia di serraggio Elemento da serrare della Quantità m·kg ft·lb filettatura M8 × 1,25 Staffa superiore e tubo esterno M8 × 1,25 Staffa inferiore e tubo esterno M24 × 1,0 Staffa superiore e cannotto dello sterzo 14,5 M8 ×...
Page 142 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Dimensioni Coppia di serraggio Elemento da serrare della Quantità m·kg ft·lb filettatura M6 × 1,0 Disco freno posteriore M8 × 1,25 Pedale del freno M6 × 1,0 Pompa freno posteriore M6 ×...
Page 143 All manuals and user guides at all-guides.com SPEC SPECIFICHE DI MANUTENZIONE Dimensioni Coppia di serraggio Elemento da serrare della Quantità m·kg ft·lb filettatura M6 × 1,0 Supporto del faro (inferiore) e staffa inferiore M6 × 1,0 Faro (sinistro e destro) M6 ×...
Page 144 Impianto di accensione: Tipo di dispositivo di anticipo Elettrico ---- CDI.: Modello/costruttore magneto F5NG 00/YAMAHA ---- 640 ~ 960 Ω a 20 ˚C (68 ˚F) Resistenza bobina di carica 1 (colore) ---- (Verde – Marrone) 464 ~ 696 Ω a 20 ˚C (68 ˚F)
Page 145 All manuals and user guides at all-guides.com SPECIFICHE RELATIVE ALLE COPPIE DI SERRAGGIO SPEC GENERALI/DEFINIZIONE DELLE UNITÀ DI MISURA SPECIFICHE RELATIVE ALLE COPPIE DI SERRAGGIO GENERALI Questo grafico specifica le coppie di serraggio per dispositivi di fissaggio convenzionali con filetti a passo convenzionale I.S.O.
Page 146 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM Î Fasten the engine stop switch 1 Hose guide I Carburetor overflow hose lead and ignition coil lead of the 2 Brake hose J Coolant reservoir breather hose sub-wire harness.
Page 147 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI KABELFÜHRUNG CHEMINEMENT DES SCHEMA DEL PER- 1 Schlauchführung CABLES CORSO DEI CAVI 2 Bremsschlauch 1 Guide de durit 1 Guida del tubo flessibile 3 Spannungsregulator 2 Durit de frein 2 Tubo flessibile del freno...
Page 148 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM Ù Ò Pass the carburetor breather Â Pass the clutch cable in front of Pass the carburetor breather hose overflow hose the radiator mounting boss. hoses and overflow hose so Í...
Page 149 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI Ò Faire passer la durit de mise à l’air du car- Ò Den Vergaser-Lüftungsschlauch und Ò Far passare il tubetto di sfiato del carbura- burateur et la durit de trop-plein entre la den Überlaufschlauch zwischen Pleu- tore e il tubo flessibile di troppopieno tra...
Page 150 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM Å Fasten the coolant reservoir breather hose and 1 Coolant reservoir breather hose 2 Radiator breather hose carburetor breather hose together. ı Pass the throttle cables along inner side of the 3 Ignition coil 4 CDI unit spark plug lead.
Page 151 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Durit de mise à l’air du vase d’expansion 1 Kühlmittelausgleichsbehälter-Lüf- 1 Tubetto di sfiato del serbatoio del liquido 2 Durit de mise à l’air du radiateur tungsschlauch di raffreddamento 3 Bobine d’allumage...
Page 152 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM Å Fasten the coolant reservoir hose and coolant 1 Coolant reservoir hose 2 Coolant reservoir breather hose reservoir breather hose. ı Do not allow the taillight lead to slacken. 3 Clamp Ç...
Page 153 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Durit du vase d’expansion 1 Kühlmittel-Ausgleichsbehält- 1 Tubo flessibile del serbatoio del liquido di 2 Durit de mise à l’air du vase d'expansion erschlauch raffreddamento 3 Bride...
Page 154 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM Å Install the brake hose to the brake caliper with the 1 Brake hose 2 Brake hose holder paint on the pipe facing the brake caliper and with 3 Brake master cylinder the pipe contacting the brake caliper projection.
Page 155 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Durit de frein 1 Bremsschlauch 1 Flessibile del freno 2 Support de durit de frein 2 Bremsschlauchhalter 2 Supporto tubo flessibile del freno 3 Maître-cylindre de frein 3 Hauptbremszylinder 3 Pompa del freno...
Page 156 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM Å Fasten the engine stop switch lead to the handlebar with the plastic 1 Throttle cable 2 Light switch band. ı Pass the decompression cable between the brake hose and clutch 3 Light switch lead 4 Clamp cable.
Page 157 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Câble des gaz 1 Gaszug 1 Cavo acceleratore 2 Contacteur d’éclairage 2 Lichtschalter 2 Interruttore luci 3 Fil de contacteur d’éclairage 3 Lichtschalterleitung 3 Cavo dell’interruttore luci 4 Bride 4 Kabelbinder...
Page 158 If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every...
Page 159 All manuals and user guides at all-guides.com INSP MAINTENANCE INTERVALS Every Every third race fifth race After Every As re- Item Remarks break-in race quired 500 km 1,000 km (300 mi) (600 mi) SHIFT FORK, SHIFT CAM, GUIDE BAR ● Inspect Inspect wear ROTOR NUT...
Page 160 Retighten sprocket bolt ● Inspect bearings ● Replace bearings ● Lubricate Lithium base grease THROTTLE, CONTROL CABLE Yamaha cable lube or ● ● Check routing and connection SAE 10W-30 motor oil ● ● Lubricate * marked : For USA 3 - 3...
Page 161 Sa machine ont une grande influence sur les intervalles d’entretien et de lubrification. En cas de doute au sujet des intervalles d’entretien et de lubrification à adopter, consulter son concessionnaire Yamaha. Chaque Chaque ème...
Page 162 All manuals and user guides at all-guides.com INSP PROGRAMME D’ENTRETIEN Chaque Chaque ème ème Après Chaque Partie néces- Remarques rodage course 500 km 1.000 km saire (300 mi) (600 mi) FOURCHETTE, BARILLET, BARRE DE GUIDAGE ● Contrôler Contrôler l’usure. ECROU DU ROTOR ●...
Page 163 Contrôler les roulements ● Remplacer les roulements ● Graisser Graisse à base de lithium ACCELERATEUR, CABLES DE COM- MANDE Yamaha lube pour câble ou Contrôler le cheminement et le branche- huile moteur SAE 10W-30 ● ● ment ● ● Graisser Astérique* : Pour les USA...
Page 164 Die hier empfohlenen Zeitabstände für Wartung und Schmierung sollten jedoch lediglich als Richt- werte für den Normalbetrieb angesehen werden. Je nach Wetterbedingungen, Belastung und Ein- satzgebiet können in Abweichung des regelmäßigen Wartungsplans kürzere Intervalle notwendig werden. Richten Sie etwaige Fragen zu den Wartungs- und Schmierintervallen bitte an Ihren Yamaha-Händler. Nach Jedes Jedes...
Page 165 All manuals and user guides at all-guides.com INSP WARTUNGSINTERVALLE UND SCHMIERDIENST Nach Jedes Jedes Nach dritte fünfte Nach Bezeichnung jedem Bemerkungen Ein- oder alle oder alle Bedarf Rennen fahren 500 km 1.000 km SCHALTGABEL, SCHALTWALZE, FÜHRUNGSSTANGE ● Prüfen Auf Verschleiß prüfen. ROTORMUTTER ●...
Page 166 All manuals and user guides at all-guides.com INSP WARTUNGSINTERVALLE UND SCHMIERDIENST Nach Jedes Jedes Nach dritte fünfte Nach Bezeichnung jedem Bemerkungen Ein- oder alle oder alle Bedarf Rennen fahren 500 km 1.000 km TELESKOPGABEL ● ● Prüfen und einstellen ● ●...
Page 167 In caso di dubbi su quali intervalli seguire per la manutenzione e la lubrificazione del veicolo, consultare il proprio rivenditore Yamaha. Ogni...
Page 168 All manuals and user guides at all-guides.com INSP INTERVALLI DI MANUTENZIONE Ogni Ogni terza Dopo il Come quinta Ad ogni oppure Elemento rodag- richie- Osservazioni oppure gara 500 km 1.000 km (300 mi) (600 mi) FORCELLA DEL CAMBIO, CAMMA DEL CAMBIO, BARRA GUIDA ●...
Page 169 Ispezionare i cuscinetti ● Sostituire i cuscinetti ● Lubrificare. Grasso a base di litio ACCELERATORE, CAVO DI Lubrificante per cavi COMANDO Yamaha o olio motore SAE ● ● Controllare il percorso e il collegamento 10W-30 ● ● Lubrificare. *contrassegnato: Per USA...
Page 170 All manuals and user guides at all-guides.com INSP PRE-OPERATION INSPECTION AND MAINTENANCE EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine...
Page 171 All manuals and user guides at all-guides.com INSP CONTROLE ET ENTRETIEN AVANT UTILISATION CONTROLE ET ENTRETIEN AVANT UTILISATION Avant la conduite pour le rodage, l’entraînement ou une course, s’assurer que la machine est en bon état de marche. Avant d’utiliser cette machine, contrôler les points suivants: CONTROLE GENERAL ET ENTRETIEN Partie Routine...
Page 172 All manuals and user guides at all-guides.com WARTUNGS- UND EINSTELLARBEITEN VOR INSP FAHRTBEGINN WARTUNGS- UND EINSTELLARBEITEN VOR FAHRTBEGINN Der Betriebszustand der Maschine muß sowohl vor dem Einfahren als auch vor jeder Übungs- und Rennfahrt überprüft werden. Vor Fahrtbeginn neben einer gewissenhaften Sichtkontrolle folgende Punkte prüfen. ROUTINEKONTROLLE VOR FAHRTBEGINN Bezeichnung Ausführung...
Page 173 All manuals and user guides at all-guides.com INSP CONTROLLI PRELIMINARI E MANUTENZIONE CONTROLLI PRELIMINARI E MANUTENZIONE Prima di mettersi alla guida per il rodaggio, per fare pratica o per la gara, accertarsi che il veicolo sia in buone condizioni di funzionamento. Prima di usare questo veicolo, controllare quanto segue: ISPEZIONE GENERALE E MANUTENZIONE Elemento...
Page 174 All manuals and user guides at all-guides.com ENGINE/COOLANT LEVEL INSPECTION/ INSP COOLANT REPLACEMENT EC350000 ENGINE EC351011 COOLANT LEVEL INSPECTION WARNING Do not remove the radiator cap 1, drain bolt and hoses when the engine and radia- tor are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.
Page 175 All manuals and user guides at all-guides.com MOTEUR/CONTROLE DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT/ CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP MOTOR/KÜHLFLÜSSIGKEITSTAND KONTROLLIEREN/KÜHLFLÜSSIGKEIT WECHSELN MOTORE/CONTROLLO DEL LIVELLO DI REFRIGERANTE/ SOSTITUZIONE LIQUIDO DI RAFFREDDAMENTO MOTOR MOTEUR MOTORE KÜHLFLÜSSIGKEITSTAND KON- CONTROLE NIVEAU CONTROLLO DEL LIVELLO DI TROLLIEREN LIQUIDE DE REFROIDISSEMENT REFRIGERANTE...
Page 176 All manuals and user guides at all-guides.com INSP COOLANT REPLACEMENT CAUTION: Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: Seat Left side cover Refer to ”SEAT FUEL TANK AND SIDE COVERS”...
Page 177 All manuals and user guides at all-guides.com CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP KÜHLFLÜSSIGKEIT WECHSELN SOSTITUZIONE LIQUIDO DI RAFFREDDAMENTO ATTENZIONE: ACHTUNG: ATTENTION: Darauf achten, daß keine Kühlflüs- Prendre garde à ne pas verser de Fare attenzione a non far cadere refri- sigkeit auf lackierte Flächen ge- liquide de refroidissement sur les sur- gerante sulle superfici verniciate.
Page 178 All manuals and user guides at all-guides.com INSP RADIATOR CAP INSPECTION CAUTION: Do not mix more than one type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be han- dled with special care.
Page 179 All manuals and user guides at all-guides.com CONTROLE DU BOUCHON DU RADIATEUR INSP KÜHLFLÜSSIGKEITSTAND KONTROLLIEREN CONTROLLO TAPPO DEL RADIATORE ATTENZIONE: ACHTUNG: ATTENTION: Auf keinen Fall verschiedene Sor- Ne pas mélanger plusieurs solutions Non mescolare più di un tipo di ten Äthylenglykol-Frostschutzmit- antigel à...
Page 180 All manuals and user guides at all-guides.com RADIATOR CAP OPENING PRESSURE INSPECTION/ INSP COOLING SYSTEM INSPECTION RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Radiator cap tester adapter: YU-33984/90890-01352 NOTE: Apply water on the radiator cap seal.
Page 181 All manuals and user guides at all-guides.com CONTROLE DE LA PRESSION D’OUVERTURE DU BOUCHON DU RADIATEUR/ CONTROLE DU SYSTEME DE REFROIDISSEMENT KÜHLERVERSCHLUSSDECKEL-ÖFFNUNGSDRUCK KONTROLLIEREN/ INSP KÜHLSYSTEM KONTROLLIEREN CONTROLLO PRESSIONE APERTURA TAPPO DEL RADIATORE/ ISPEZIONE DEL SISTEMA DI RAFFREDDAMENTO KÜHLERVERSCHLUSSDECKEL- CONTROLE DE LA PRESSION CONTROLLO PRESSIONE APER- ÖFFNUNGSDRUCK KONTROLLIE- D’OUVERTURE DU BOUCHON DU...
Page 182 All manuals and user guides at all-guides.com INSP CLUTCH ADJUSTMENT NOTE: Do not apply pressure more than specified pressure. Radiator should be filled fully. 4. Inspect: Pressure Impossible to maintain the specified pressure for 10 seconds → Repair. Radiator 1 Radiator hose joint 2 Coolant leakage →...
Page 183 All manuals and user guides at all-guides.com REGLAGE DE L’EMBRAYAGE INSP KUPPLUNG EINSTELLEN REGOLAZIONE FRIZIONE HINWEIS: N.B.: NOTA: Ne pas appliquer de pression supé- Den vorgeschriebenen Druck nicht Non applicare pressione superiore a rieure à la pression spécifiée. Überschreiten. quella specificata. Der Kühler muß...
Page 184 All manuals and user guides at all-guides.com INSP THROTTLE CABLE ADJUSTMENT THROTTLE CABLE ADJUSTMENT 1. Check: Throttle grip free play a Out of specification → Adjust. Throttle grip free play a: 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Adjust: Throttle grip free play Throttle grip free play adjustment steps: Remove the throttle cable cap 1 and...
Page 185 All manuals and user guides at all-guides.com REGLAGE DES CABLES DES GAZ INSP GASZUGSPIEL EINSTELLEN REGOLAZIONE DEL CAVO DELL’ACCELERATORE GASZUGSPIEL EINSTELLEN REGLAGE DES CABLES DES GAZ REGOLAZIONE CAVO 1. Kontrollieren: Vérifier: DELL’ACCELERATORE Jeu à la poignée des gaz a Gaszugspiel a Controllare: Hors spécification →...
Page 186 All manuals and user guides at all-guides.com THROTTLE LUBRICATION/ INSP DECOMPRESSION ADJUSTMENT THROTTLE LUBRICATION 1. Remove: Rubber cover 1 Throttle grip cap 2 2. Apply: Lithium soap base grease On the throttle cable end a. 3. Install: Throttle grip cap Screw (throttle grip cap) 4 Nm (0.4 m ·...
Page 187 All manuals and user guides at all-guides.com INSP GRAISSAGE DE L’ACCELERATEUR/REGLAGE DE LA DECOMPRESSION GASZUG SCHMIEREN/EINSTELLUNG DER DEKOMPRESSION LUBRIFICAZIONE DELL’ACCELERATORE/REGOLAZIONE DECOMPRESSIONE GASZUG SCHMIEREN GRAISSAGE DE L’ACCELERA- LUBRIFICAZIONE DELL’ACCE- 1. Demontieren: TEUR LERATORE Gummiabdeckung 1 Déposer: Rimuovere: Couvercle en caoutchouc 1 Gasdrehgriffkappe 2 Coperchio di gomma 1 Logement de la poignée des...
Page 188 All manuals and user guides at all-guides.com INSP AIR FILTER CLEANING 2. Adjust: Decompression lever free play Adjustment steps: Loosen the locknut 1. Turn the adjuster 2 in or out until the adjustment is suitable. Tighten the locknut. CAUTION: After the adjustment, start the engine and make sure that the engine does not stop when the handlebar is turned fully both ways.
Page 189 All manuals and user guides at all-guides.com NETTOYAGE DU FILTRE A AIR INSP LUFTFILTER REINIGEN PULIZIA FILTRO DELL’ARIA 2. Einstellen: Régler: Regolare: Dekompressionszugspiel Jeu au levier de décompression Gioco della leva della decom- am Hebeldrehpunkt pressione Etapes du réglage: Desserrer le contre-écrou 1. Arbeitsschritte Fasi di regolazione: Die Sicherungsmutter 1 lok-...
Page 190 All manuals and user guides at all-guides.com INSP AIR FILTER CLEANING 5. Clean: Air filter element Clean them with solvent. NOTE: After cleaning, remove the remaining solvent by squeezing the element. CAUTION: Do not twist the element when squeezing the element. Leaving too much of solvent in the ele- ment may result in poor starting.
Page 191 All manuals and user guides at all-guides.com NETTOYAGE DU FILTRE A AIR INSP LUFTFILTER REINIGEN PULIZIA FILTRO DELL’ARIA 5. Reinigen: Nettoyer: Pulire: Luftfittereinsatz Elément du filtre à air Elemento filtrante (in Lösungsmittel) Le nettoyer avec du dissolvant. Pulire con solvente. HINWEIS: N.B.: NOTA:...
Page 192 All manuals and user guides at all-guides.com INSP ENGINE OIL LEVEL INSPECTION 10. Install: Air filter element 1 Washer Fitting bolt 2 Nm (0.2 m · kg, 1.4 ft · lb) NOTE: Align the projection a on filter guide with the hole b in air filter case.
Page 193 All manuals and user guides at all-guides.com CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN CONTROLLO DEL LIVELLO DELL’OLIO MOTORE 10. Montieren: 10. Monter: 10. Installare: Elément de filtre à air 1 Luftfittereinsatz 1 Elemento filtrante 1 Scheibe Rondelle Rondella Schraube Boulon de fixation Bullone di fissaggio...
Page 194 All manuals and user guides at all-guides.com INSP ENGINE OIL LEVEL INSPECTION (For USA and CDN) Recommended oil: At 5 ˚C (40 ˚F) or higher Å Yamalube 4 (20W-40) or SAE 20W-40 type SH motor oil (Non-Friction modified) At 15 ˚C (60 ˚F) or lower ı Yamalube 4 (10W-30) or SAE 10W-30 type SH motor oil (Non-Friction modified)
Page 195 All manuals and user guides at all-guides.com CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN CONTROLLO DEL LIVELLO DELL’OLIO MOTORE Nur USA und CDN: (Pour les USA et le CDN) (Per USA e CDN) Huile recommandée: Empfohlene Ölsorte (Vis- Olio raccomandato: Min.
Page 196 All manuals and user guides at all-guides.com INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT 1. Start the engine and warm it up for sev- eral minutes, and then turn off the engine and wait for five minute. 2. Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine.
Page 197 All manuals and user guides at all-guides.com CHANGEMENT DE L’HUILE DE MOTEUR INSP MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTORE MOTORÖL WECHSELN CHANGEMENT DE L’HUILE DE SOSTITUZIONE DELL’OLIO 1. Den Motor starten, mehrere MOTEUR MOTORE Minuten warmlaufen lassen, Mettre le moteur en marche, le Avviare il motore, riscaldarlo per und dann ausschalten und faire chauffer pendant quelques...
Page 198 All manuals and user guides at all-guides.com INSP ENGINE OIL REPLACEMENT 7. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them. Replacement steps: Remove the oil filter element cover 1 and oil filter element 2.
Page 199 All manuals and user guides at all-guides.com CHANGEMENT DE L’HUILE DE MOTEUR INSP MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTORE 7. Soll auch der Ölfilter gewech- S’il est nécessaire de remplacer le Se è necessario sostituire il filtro selt werden, müssen zusätz- filtre à...
Page 200 All manuals and user guides at all-guides.com OIL PRESSURE INSPECTION/ INSP PILOT SCREW ADJUSTMENT OIL PRESSURE INSPECTION 1. Check: Oil pressure Checking steps: Slightly loosen the oil pressure check bolt Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt.
Page 201 All manuals and user guides at all-guides.com CONTROLE DE LA PRESSION D’HUILE/REGLAGE DE LA VIS DE RICHESSE INSP ÖLDRUCKPRÜFUNG/LEERLAUFGEMISCH EINSTELLEN CONTROLLO PRESSIONE DELL’OLIO/ REGOLAZIONE DELLA VITE DI REGISTRO DEL MINIMO ÖLDRUCKPRÜFUNG CONTROLE DE LA PRESSION CONTROLLO PRESSIONE 1. Kontrollieren: D’HUILE DELL’OLIO Öldruck Contrôler:...
Page 202 All manuals and user guides at all-guides.com ENGINE IDLING SPEED ADJUSTMENT/ INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT ENGINE IDLING SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it 2. Attach: Inductive tachometer To spark plug lead. 3. Adjust: Engine idling speed Adjustment steps: Adjust the pilot screw.
Page 203 All manuals and user guides at all-guides.com REGLAGE DU REGIME DE RALENTI/CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP LEERLAUFDREHZAHL EINSTELEN/VENTILSPIEL KONTROLLIEREN UND EINSTELLEN REGOLAZIONE DEL MINIMO/CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE LEERLAUFDREHZAHL EINSTE- REGLAGE DU REGIME DE REGOLAZIONE DEL MINIMO RALENTI Avviare e riscaldare bene il 1.
Page 204 All manuals and user guides at all-guides.com INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT 3. Remove: Right radiator Refer to “RADIATOR” section in the CHAPTER 4. Carburetor Refer to “CARBURETOR” section in the CHAPTER 4. Spark plug Upper engine bracket Cylinder head cover Refer to “CAMSHAFTS”...
Page 205 All manuals and user guides at all-guides.com CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE 3. Demontieren: Déposer: Rimuovere: Rechter Kühler Radiateur de droite Radiatore destro Siehe Abschnitt “KÜHLER” reporter à...
Page 206 All manuals and user guides at all-guides.com INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Checking steps: Turn the crankshaft counterclockwise with a wrench. NOTE: Squeezing the decompression lever allows the crankshaft to be turned easily. Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C.
Page 207 All manuals and user guides at all-guides.com CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Arbeitsschritte Étapes de la vérification: Fasi di controllo: Kurbelwelle mit einem Schrau- Faire tourner le vilebrequin dans le Ruotare l’albero motore in senso sens inverse des aiguilles d’une benschlüssel gegen den Uhr-...
Page 208 All manuals and user guides at all-guides.com INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Remove the decompression cable 1, guide 2, bolt 3 and decompression shaft Remove the valve lifters 5 and the pads NOTE: Place a rag in the timing chain space to prevent pads from falling into the crank- case.
Page 209 All manuals and user guides at all-guides.com CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Dekompressionszug 1, Füh- Déposer le câble de décompression Rimuovere il cavo di decompres- 1, le guide 2, le boulon 3 et l’a rung 2, Schraube 3 und De- sione 1, la guida 2, il bullone 3 de décompresseur 4.
Page 210 All manuals and user guides at all-guides.com INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Locate the rounded-off value and the measured valve clearance in the chart “PAD SELECTION TABLE”. The field where these two coordinates intersect shows the new pad number to use. NOTE: Use the new pad number only as a guide when verifying the valve clearance adjust-...
Page 211 All manuals and user guides at all-guides.com CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Gerundete Ventilplättchen- Trouver la valeur arrondie et la Individuare il valore arrotondato Nummer und gemessenes Ven- valeur mesurée du jeu de soupapes ed il gioco della valvola misurato sur la “TABLE DE SELECTION...
Page 212 All manuals and user guides at all-guides.com INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT INTAKE INSTALLED PAD NUMBER MEASURED CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09...
Page 213 All manuals and user guides at all-guides.com INSP CONTROLE ET REGLAGE DU JEU DE SOUPAPES ADMISSION NUMERO DE CALE INSTALLEE JEU MESURE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00 à...
Page 214 All manuals and user guides at all-guides.com INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN EINLASS GEMESSE- NUMMER DES AUSGEBAUTEN VENTILPLÄTTCHENS NES SPIEL 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00–0,04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0,05–0,09...
Page 215 All manuals and user guides at all-guides.com INSP CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE ASPIRAZIONE GIOCO NUMERO SPESSORE INSTALLATO MISURATO 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00 ~ 0,04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0,05 ~ 0,09...
Page 216 All manuals and user guides at all-guides.com INSP SPARK ARRESTER CLEANING (For USA) SPARK ARRESTER CLEANING (For USA) WARNING Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. Do not start the engine when cleaning the exhaust system.
Page 217 All manuals and user guides at all-guides.com NETTOYAGE DU PARE-ETINCELLES (pour les USA)/ INSP FUNKENFÄNGER REINIGEN (NUR USA) PULIZIA DEL PARASCINTILLE (Per USA) FUNKENFÄNGER REINIGEN (NUR NETTOYAGE DU PARE-ETINCEL- PULIZIA DEL PARASCINTILLE USA) LES (pour les USA) (Per USA) AVVERTENZA WARNUNG AVERTISSEMENT Le tuyau et le pot d’échappement...
Page 218 All manuals and user guides at all-guides.com INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING WARNING Bleed the brake system if: The system has been disassembled. A brake hose has been loosened or removed. The brake fluid is very low. The brake operation is faulty.
Page 219 All manuals and user guides at all-guides.com INSP PARTIE CYCLE/PURGE DE L’AIR DU SYSTEME DE FREINAGE FAHRWERK/HYDRAULISCHE BREMSANLAGE ENTLÜFTEN PARTE CICLISTICA/SPURGO DELL’ARIA DAL SISTEMA FRENANTE FAHRWERK PARTIE CYCLE PARTE CICLISTICA HYDRAULISCHE BREMSANLAGE PURGE DE L’AIR DU SYSTEME SPURGO DELL’ARIA DAL ENTLÜFTEN DE FREINAGE SISTEMA FRENANTE...
Page 220 All manuals and user guides at all-guides.com INSP FRONT BRAKE ADJUSTMENT NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disap- peared.
Page 221 All manuals and user guides at all-guides.com REGLAGE DE FREIN AVANT INSP VORDERRADBREMSE EINSTELLEN REGOLAZIONE DEL FRENO ANTERIORE HINWEIS: NOTA: N.B.: Kann die Anlage nicht zufrieden- Si la purge est difficile, il peut être Se lo spurgo risulta difficoltoso, stellend entlüftet werden, sollte die nécessaire de laisser le système du potrebbe essere necessario lasciar Bremsflüssigkeit einige Stunden...
Page 222 All manuals and user guides at all-guides.com REAR BRAKE ADJUSTMENT/ INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMENT 1. Check: Brake pedal height a Out of specification → Adjust. Brake pedal height a: 5 mm (0.20 in) 2.
Page 223 All manuals and user guides at all-guides.com REGLAGE DU FREIN ARRIERE/ CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN AVANT HINTERRADBREMSE EINSTELLEN/ INSP VORDERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN REGOLAZIONE DEL FRENO POSTERIORE/ ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE HINTERRADBREMSE EINSTEL- REGLAGE DU FREIN ARRIERE REGOLAZIONE FRENO...
Page 224 All manuals and user guides at all-guides.com INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT Loosen the pad pin 2. Remove the brake hose holder 3 and brake caliper 4 from the front fork. Remove the pad pin and brake pads 5. Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end.
Page 225 All manuals and user guides at all-guides.com INSP CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN AVANT VORDERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE Haltestift 2 demontieren. Svitare la spina della pastiglia 2. Desserrer la goupille de plaquette Bremsschlauchhalterung Rimuovere il supporto tubo flessi- Déposer le support de la durit de...
Page 226 All manuals and user guides at all-guides.com INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT Install the pad pin plug B. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION”...
Page 227 All manuals and user guides at all-guides.com INSP CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN ARRIERE HINTERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE Haltestift B montieren. Installare la spina delle pastiglie B. Installer le bouchon de goupille de plaquette B.
Page 228 All manuals and user guides at all-guides.com INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT Remove the pad pin 6 and brake pads 7. Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. Loosen the bleed screw and push the brake caliper piston in.
Page 229 All manuals and user guides at all-guides.com INSP CONTROLE DE L’ISOLANT DE LA PLAQUETTE DE FREIN ARRIERE HINTERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE Déposer la goupille de plaquette 6 Haltestift 6 und Bremsbeläge Rimuovere la spina delle pastiglie et les plaquettes de frein 7.
Page 230 All manuals and user guides at all-guides.com REAR BRAKE PAD INSULATOR INSPECTION/ INSP BRAKE FLUID LEVEL INSPECTION 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: Brake pedal operation A softy or spongy feeling → Bleed brake system.
Page 231 All manuals and user guides at all-guides.com CONTROLE DE L’ISOLANT DE LA PLAQUETTE DE FREIN ARRIERE/ CONTROLE DU NIVEAU DU LIQUIDE DE FREIN INSPEKTION DER ISOLIERUNG DES HINTERRADBREMSBELAGS/ BREMSFLÜSSIGKEITSSTAND KONTROLLIEREN INSP ISPEZIONE DELL’ISOLANTE DELLA PASTIGLIA DEL FRENO POSTERIORE/ CONTROLLO DEL LIVELLO DEL LIQUIDO DEI FRENI 3.
Page 232 All manuals and user guides at all-guides.com INSP SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION SPROCKETS INSPECTION 1. Inspect: Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive sprocket, rear wheel sprocket and drive chain as a set. DRIVE CHAIN INSPECTION 1.
Page 233 All manuals and user guides at all-guides.com INSP CONTROLE DES PIGNONS/CONTROLE DE LA CHAINE DE TRANSMISSION KETTENRÄDER KONTROLLIEREN/ANTRIEBSKETTE KONTROLLIEREN ISPEZIONE DELLE CORONE DENTATE/ISPEZIONE DELLA CATENA DI TRASMISSIONE KETTENRÄDER KONTROLLIE- CONTROLE DES PIGNONS ISPEZIONE DELLE CORONE DEN- Contrôler: TATE Dents de pignon a 1.
Page 234 All manuals and user guides at all-guides.com INSP DRIVE CHAIN SLACK ADJUSTMENT 5. Install: Chain joint 1 O-ring 2 Drive chain 3 NOTE: When installing the drive chain, apply the lith- ium soap base grease on the chain joint and O-rings.
Page 235 All manuals and user guides at all-guides.com REGLAGE DE LA FLECHE DE CHAINE DE TRANSMISSION INSP ANTRIEBSKETTEN-DURCHHANG EINSTELLEN REGOLAZIONE DELLA TENSIONE DELLA CATENA DI TRASMISSIONE 5. Montieren: Monter: Installare: Raccord de chaîne 1 Kettenschloß 1 Giunto della catena 1 Joint torique 2 O-Ring 2 O-ring 2 Chaîne de transmission 3...
Page 236 All manuals and user guides at all-guides.com INSP FRONT FORK INSPECTION 3. Adjust: Drive chain slack Drive chain slack adjustment steps: Loosen the axle nut 1 and locknuts 2. Adjust chain slack by turning the adjusters To tighten → Turn adjuster 3 counter- clockwise.
Page 237 All manuals and user guides at all-guides.com CONTROLE DE LA FOURCHE AVANT INSP TELESKOPGABEL KONTROLLIEREN ISPEZIONE FORCELLA ANTERIORE 3. Einstellen: Régler: Regolare: Antriebsketten-Durchhang Flèche de chaîne de transmis- Allentamento catena di tra- sion smissione Arbeitsschritte Achsmutter 1 und Sicherungs- Etapes de réglage de flèche de Fasi di regolazione allentamento muttern 2 lockern.
Page 238 All manuals and user guides at all-guides.com FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ INSP FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1. Remove: Protector Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.
Page 239 All manuals and user guides at all-guides.com NETTOYAGE DE BAGUE D’ETANCHEITE ET DE JOINT ANTIPOUSSIERE DE FOURCHE AVANT/REGLAGE DE LA FORCE D’AMORTISSEMENT DE DETENTE DE LA FOURCHE AVANT GABELDICHTRING UND STAUBMANSCHETTE REINIGEN/ TELESKOPGABEL-ZUGSTUFENDÄMPFUNG EINSTELLEN INSP PULIZIA DEL PARAOLIO E DEL PARAPOLVERE DELLE FORCELLE ANTERIORI/ REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI ESPANSIONE DELLA FORCELLA ANTERIORE GABELDICHTRING UND STAUB-...
Page 240 All manuals and user guides at all-guides.com FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting.
Page 241 All manuals and user guides at all-guides.com REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION DE LA FOURCHE AVANT INSP TELESKOPGABEL-DRUCKSTUFEN-DÄMPFUNG EINSTELLEN REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI COMPRESSIONE DELLA FORCELLA ANTERIORE ATTENZIONE: ACHTUNG: ATTENTION: Einstellmechanismus Ne pas forcer le dispositif de réglage Non forzare il registro oltre il minimo über die Minimal- oder Maximal- au-delà...
Page 242 All manuals and user guides at all-guides.com INSP REAR SHOCK ABSORBER INSPECTION STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. Standard position: 10 clicks out **15 clicks out * For EUROPE ** For AUS, NZ and ZA CAUTION:...
Page 243 All manuals and user guides at all-guides.com CONTROLE DE L’AMORTISSEUR ARRIERE INSP FEDERBEIN KONTROLLIEREN ISPEZIONE DELL’AMMORTIZZATORE POSTERIORE Normaleinstellung POSITION STANDARD: POSIZIONE STANDARD: Zum Erreichen der Normaleinstel- C’est la position qui se trouve en Questa è la posizione raggiunta con un lung die Einstellschraube nach arrière du nombre spécifié...
Page 244 All manuals and user guides at all-guides.com REAR SHOCK ABSORBER SPRING PRELOAD INSP ADJUSTMENT EC36M013 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: Rear frame 3. Loosen: Locknut 1 4.
Page 245 All manuals and user guides at all-guides.com REGLAGE DE LA PRECONTRAINTE DE RESSORT DE L’AMORTISSEUR ARRIERE INSP FEDERBEIN-FEDERVORSPANNUNG EINSTELLEN REGOLAZIONE DEL PRECARICO DELLA MOLLA DELL’AMMORTIZZATORE POSTERIORE FEDERBEIN-FEDERVORSPAN- REGLAGE DE LA PRECON- REGOLAZIONE DEL PRECARICO NUNG EINSTELLEN TRAINTE DE RESSORT DE DELLA MOLLA DELL’AMMOR- 1.
Page 246 All manuals and user guides at all-guides.com REAR SHOCK ABSORBER REBOUND INSP DAMPING FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damp- ing force.
Page 247 All manuals and user guides at all-guides.com REGLAGE DE LA FORCE D’AMORTISSEMENT DE DETENTE DE L’AMORTISSEUR ARRIERE FEDERBEIN-ZUGSTUFENDÄMPFUNG EINSTELLEN INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI ESPANSIONE DELL’AMMORTIZZATORE POSTERIORE FEDERBEIN-ZUGSTUFENDÄMP- REGLAGE FORCE REGOLAZIONE DELLA FORZA DI FUNG EINSTELLEN D’AMORTISSEMENT DE DETENTE SMORZAMENTO DI ESPANSIONE 1.
Page 248 All manuals and user guides at all-guides.com REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: Low compression damping force By turning the adjuster 1. Stiffer a → Increase the low compres- sion damping force.
Page 249 All manuals and user guides at all-guides.com REGLAGE DE LA FORCE D’AMORTISSEMENT A BASSE COMPRESSION DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER FEDERBEIN-DRUCKSTUFENDÄMPFUNG INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI BASSA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE EINSTELLUNG DER FEDERBEIN- REGLAGE FORCE REGOLAZIONE DELLA FORZA DI DRUCKSTUFENDÄMPFUNG D’AMORTISSEMENT BASSE...
Page 250 All manuals and user guides at all-guides.com REAR SHOCK ABSORBER HIGH COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: High compression damping force By turning the adjuster 1. Stiffer a → Increase the high compres- sion damping force.
Page 251 All manuals and user guides at all-guides.com REGLAGE DE LA FORCE D’AMORTISSEMENT A HAUTE COMPRESSION DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER FEDERBEIN-DRUCKSTUFENDÄMPFUNG INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI COMPRESSIONE ALTA DELL’AMMORTIZZATORE POSTERIORE EINSTELLUNG DER FEDERBEIN- REGLAGE FORCE REGOLAZIONE DELLA FORZA DI DRUCKSTUFENDÄMPFUNG D’AMORTISSEMENT A HAUTE SMORZAMENTO DI COMPRES-...
Page 252 All manuals and user guides at all-guides.com TIRE PRESSURE CHECK/SPOKES INSPECTION AND INSP TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kg/cm , 15 psi) NOTE: Check the tire while it is cold. Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
Page 253 All manuals and user guides at all-guides.com CONTROLE DE PRESSION DES PNEUS/ CONTROLE ET SERRAGE DES RAYONS/CONTROLE DE LA ROUE REIFENLUFTDRUCK KONTROLLIEREN/ INSP SPEICHEN KONTROLLIEREN UND FESTZIEHEN/RÄDER KONTROLLIEREN CONTROLLO DELLA PRESSIONE DEI PNEUMATICI/ ISPEZIONE E SERRAGGIO DEI RAGGI/ISPEZIONE DELLE RUOTE REIFENLUFTDRUCK KONTROL- CONTROLE DE PRESSION DES...
Page 254 All manuals and user guides at all-guides.com INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: Bearing free play Exist play → Replace. STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine. 2.
Page 255 All manuals and user guides at all-guides.com CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPF KONTROLLIEREN UND EINSTELLEN ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO 2. Kontrollieren: Vérifier: Ispezionare: Lagerspiel Jeu de roulement Gioco del cuscinetto Il y a du jeu → Remplacer. Spiel →...
Page 256 All manuals and user guides at all-guides.com INSP STEERING HEAD INSPECTION AND ADJUSTMENT Tighten the steering ring nut 3 using steering nut wrench 4. NOTE: Set the torque wrench to the steering nut wrench so that they form a right angle. Steering nut wrench: YU-33975/90890-01403 Steering ring nut (initial tighten-...
Page 257 All manuals and user guides at all-guides.com CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPF KONTROLLIEREN UND EINSTELLEN ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO Ringmutter 3 mit dem Haken- Avvitare la ghiera 3 utilizzando la Serrer l’écrou crénelé de direction 3 en utilisant la clé...
Page 258 All manuals and user guides at all-guides.com INSP LUBRICATION Å Use Yamaha cable lube or equivalent on these LUBRICATION areas. To ensure smooth operation of all compo- ı Use SAE 10W-30 motor oil or suitable chain nents, lubricate your machine during setup, lubricants.
Page 259 0 Dekompressionszugende Å Yamaha Seilzug-Schmiermittel oder 0 Extrémité du câble de décompresseur cavi Yamaha o equivalente. Å Mettre du lubrifiant Yamaha pour câbles, gleichwertiges Mittel verwenden. ı Utilizzare olio motore SAE 10W-30 o ou équivalent sur ces parties. ı Motoröl oder Spezial-Kettenspray ver- lubrificanti per catena idonei.
Page 260 All manuals and user guides at all-guides.com 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 →...
Page 261 All manuals and user guides at all-guides.com PARTIE ELECTRIQUE/CONTROLE DE LA BOUGIE INSP ELEKTRISCHE ANLAGE/ZÜNDKERZE KONTROLLIEREN PARTE ELETTRICA/ISPEZIONE DELLA CANDELA ELEKTRISCHE ANLAGE PARTIE ELECTRIQUE PARTE ELETTRICA ZÜNDKERZE KONTROLLIEREN CONTROLE DE LA BOUGIE ISPEZIONE DELLA CANDELA 1. Demontieren: Déposer: Rimuovere: Zündkerze Bougie Candela d’accensione 2.
Page 262 All manuals and user guides at all-guides.com INSP IGNITION TIMING CHECK IGNITION TIMING CHECK 1. Remove: Timing mark accessing screw 1 2. Attach: Timing light Inductive tachometer To the spark plug lead. Timing light: YM-33277-A/90890-03141 Inductive tachometer: YU-08036-B Engine tachometer: 90890-03113 3.
Page 263 All manuals and user guides at all-guides.com CONTROLE DE L’AVANCE A L’ALLUMAGE INSP ZÜNDZEITPUNKT KONTROLLIEREN CONTROLLO DELLA FASATURA DI ACCENSIONE ZÜNDZEITPUNKT KONTROLLIE- CONTROLE DE L’AVANCE A CONTROLLO DELLA FASATURA L’ALLUMAGE DI ACCENSIONE 1. Demontieren: Déposer: Rimuovere: Steuermarkierung-Zugangs- Vis d’accès du repère de distri- Vite di accesso al riferimento bution 1 schraube 1...
Page 264 All manuals and user guides at all-guides.com INSP REPLACING THE HEADLIGHT BULBS REPLACING THE HEADLIGHT BULBS 1. Remove: Headlight Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAP- TER 4. 2. Remove: Headlight bulb holder cover 1 3.
Page 265 All manuals and user guides at all-guides.com REMPLACER LES AMPOULES DU PHARE INSP SCHEINWERFERLAMPE AUSWECHSELN SOSTITUZIONE DELLE LAMPADE DEL FARO SCHEINWERFERLAMPE AUS- REMPLACER LES AMPOULES DU SOSTITUZIONE DELLE LAM- WECHSELN PHARE PADE DEL FARO 1. Demontieren: Déposer: Rimuovere: Scheinwerfer Phare Faro Siehe Abschnitt “SITZ- Se référer à...
Page 266 All manuals and user guides at all-guides.com INSP ADJUSTING THE HEADLIGHT BEAMS ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: Headlight beam (vertically) Adjusting steps: Turn the adjusting screw 1 in direction a or b. Direction a Headlight beam is raised. Direction b Headlight beam is lowered.
Page 267 All manuals and user guides at all-guides.com REGLAGES DES FAISCEAUX DES PHARES INSP SCHEINWERFER EINSTELLEN REGOLAZIONE DEI FASCI DI LUCE DEL FARO SCHEINWERFER EINSTELLEN REGLAGES DES FAISCEAUX DES REGOLAZIONE DEI FASCI DI 1. Einstellen: PHARES LUCE DEL FARO Scheinwerferstellung (ver- Régler: Regolare: tikal)
Page 268 All manuals and user guides at all-guides.com SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE SEAT, FUEL TANK AND SIDE COVERS Extent of removal: 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Headlight removal Extent of removal Order Part name Q’ty...
Page 269 All manuals and user guides at all-guides.com SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX SITZBANK, KRAFTSTOFFTANK UND SEITENABDECKUNGEN SELLA, SERBATOIO CARBURANTE E CARENATURA LATERALE MOTEUR SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX Organisation de la dépose: 1 Dépose du selle 2 Dépose du réservoir de carburant 3 Dépose des caches latéraux 4 Dépose du phare...
Page 270 All manuals and user guides at all-guides.com EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER Å Except for USA Extent of removal: 1 Silencer removal 2 Exhaust pipe removal Extent of removal Order Part name Q’ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover...
Page 271 All manuals and user guides at all-guides.com TUYAU D’ECHAPPEMENT ET SILENCIEUX KRÜMMER UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE TUYAU D’ECHAPPEMENT ET SILENCIEUX Å Excepté pour USA Organisation de la dépose: 1 Dépose du silencieux 2 Dépose du tuyau d’échappement Organisation de la dépose Ordre Nom de pièce...
Page 272 All manuals and user guides at all-guides.com EXHAUST PIPE AND SILENCER INSPECTION Silencer and exhaust pipe 1. Inspect: Gasket 1 Damage → Replace. ASSEMBLY AND INSTALLATION Silencer and exhaust pipe 1. Install: Gasket Exhaust pipe 1 Nut (exhaust pipe) 2 13 Nm (1.3 m ·...
Page 273 All manuals and user guides at all-guides.com TUYAU D’ECHAPPEMENT ET SILENCIEUX KRÜMMER UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE PRÜFUNG CONTROLE ISPEZIONE Schalldämpfer und krümmer Silencieux et tuyau d’échappement Silenziatore e tubo di scarico 1. Kontrollieren: Contrôler: Ispezionare: Joint 1 Dichtung 1 Guarnizione 1 Endommagement →...
Page 274 All manuals and user guides at all-guides.com RADIATOR EC450001 RADIATOR Extent of removal: 1 Radiator removal Extent of removal Order Part name Q’ty Remarks RADIATOR REMOVAL Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Seat, fuel tank and left Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
Page 275 All manuals and user guides at all-guides.com RADIATEUR KÜHLER RADIATORE RADIATEUR Organisation de la dépose: 1 Dépose du radiateur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU RADIATEUR Préparation à la dépose Vidanger le liquide de refroidissement. Se reporter à...
Page 276 All manuals and user guides at all-guides.com RADIATOR EC456000 HANDLING NOTE WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.
Page 277 All manuals and user guides at all-guides.com RADIATEUR KÜHLER RADIATORE HANDHABUNGSHINWEIS REMARQUES CONCERNANT LA NOTA PER LA MANIPOLAZIONE MANIPULATION AVVERTENZA WARNUNG AVERTISSEMENT Der heiße Kühler steht unter Non rimuovere il tappo del radiatore a Ne jamais enlever le bouchon du Druck.
Page 278 All manuals and user guides at all-guides.com RADIATOR 3. Install: Right radiator 1 Bolt (right radiator) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) Radiator hose 3 3 Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2. 4.
Page 279 All manuals and user guides at all-guides.com RADIATEUR KÜHLER RADIATORE 3. Montieren: Monter: Installare: Radiateur de droite 1 Rechter Kühler 1 Radiatore destro 1 Boulon (radiateur droite) 2 Schraube (rechter Kühler) Bullone (radiatore destro) 2 10 Nm (1,0 m · kg, 7,2 ft · lb) 10 Nm (1,0 m ·...
Page 280 All manuals and user guides at all-guides.com CARBURETOR CARBURETOR Extent of removal: 1 Carburetor removal Extent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Clamp Throttle position sensor lead cou- pler...
Page 281 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE CARBURATEUR Organisation de la dépose: 1 Dépose du carburateur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU CARBURATEUR Préparation à la dépose Selle et réservoir de carburant Se reporter à...
Page 282 All manuals and user guides at all-guides.com CARBURETOR EC468000 CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring...
Page 283 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE DEMONTAGE DU CARBURATEUR 1 Démontage du carburateur Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEMONTAGE DU CARBURATEUR Durit de mise à l’air de carburateur Couvercle de logement de levier de soupape Vis (axe d’accélérateur) Boisseau...
Page 284 All manuals and user guides at all-guides.com CARBURETOR Extent of removal Order Part name Q’ty Remarks Float Needle valve Valve seat Main jet Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Intake joint Pilot air jet Main air jet...
Page 285 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE Organisation de la dépose Ordre Nom de pièce Qté Remarques Flotteur Pointeau Siège de pointeau Gicleur principal Gicleur de ralenti Entretoise Gicleur de starter Puits d’aiguille Tige de poussée Tirer la tige de poussée. Ensemble de l’axe de papillon Ensemble du levier de timonerie de tige de commande...
Page 286 All manuals and user guides at all-guides.com CARBURETOR HANDLING NOTE CAUTION: Do not loosen the screws (throttle position sensor) 1 except when changing the throt- tle position sensor due to failure because it will cause a drop in engine performance. REMOVAL POINTS Pilot screw 1.
Page 287 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE HINWEIS ZUM HANDLING REMARQUE CONCERNANT LES NOTA PER LA MANIPOLAZIONE MANIPULATIONS ATTENZIONE: ACHTUNG: ATTENTION: (Drosselklappen-Positions- Non svitare le viti (sensore di posi- Ne pas desserrer les vis (capteur de sensor) 1 nicht lösen – außer zione dell’acceleratore) 1 se non per position du papillon des gaz) 1 sauf wenn der Drosselklappen-Positi-...
Page 288 All manuals and user guides at all-guides.com CARBURETOR 2. Inspect: Main jet 1 Pilot jet 2 Needle jet 3 Starter jet 4 Main air jet 5 Pilot air jet 6 Leak jet 7 Damage → Replace. Contamination → Clean. NOTE: Use a petroleum based solvent for cleaning.
Page 289 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE 2. Kontrollieren: Contrôler: Ispezionare: Gicleur principal 1 Hauptdüse 1 Getto del massimo 1 Gicleur de ralenti 2 Leerlaufdüse 2 Getto del minimo 2 Puits d’aiguille 3 Nadeldüse 3 Getto a spillo 3 Gicleur de starter 4 Choke-Düse 4 Getto di avviamento 4...
Page 290 All manuals and user guides at all-guides.com CARBURETOR Float height 1. Measure: Float height a Out of specification → Adjust. Float height: 8.0 mm (0.31 in) Measurement and adjustment steps: Hold the carburetor in an upside down position. NOTE: Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm.
Page 291 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE Schwimmerhöhe Hauteur du flotteur Altezza galleggiante 1. Messen: Mesurer: Misurare: Hauteur du flotteur a Schwimmerhöhe a Altezza galleggiante a Hors spécification → Régler. Unvorschriftsmäßig → Ein- Fuori specifica → Regolare. stellen.
Page 292 All manuals and user guides at all-guides.com CARBURETOR Starter plunger 1. Inspect: Cold starter plunger 1 Hot starter plunger (red) 2 Wear/damage → Replace. Accelerator pump 1. Inspect: Diaphragm (accelerator pump) 1 Spring (accelerator pump) 2 Accelerator pump cover 3 O-ring 4 Push rod 5 Tears (diaphragm)/damage →...
Page 293 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE Choke-Schieber Plongeur de starter Stantuffo dell’avviamento 1. Kontrollieren: Contrôler: Ispezionare: Kaltstarter-Tauchkolben 1 Plongeur de démarrage à froid Stantuffo dell’avviamento a Heißstarter-Tauchkolben freddo 1 (rot) 2 Plongeur de démarrage à chaud Stantuffo dell’avviamento a Verschleiß/Beschädigung →...
Page 294 All manuals and user guides at all-guides.com CARBURETOR 2. Install: Main air jet 1 Pilot air jet 2 Intake joint 3 5 Nm (0.5 m · kg, 3.6 ft · lb) 3. Install: Spring 1 1 Lever 1 2 To lever 2 3. NOTE: Make sure the spring 1 fits on the stopper a of the lever 2.
Page 295 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE 2. Montieren: Monter: Installare: Gicleur d’air principal 1 Hauptluftdüse 1 Getto dell’aria del massimo 1 Gicleur d’air de ralenti 2 Leerlaufluftdüse 2 Getto dell’aria del minimo 2 Raccord d’admission 3 Ansaugstutzen 3 Giunto ammissione 3 5 Nm (0,5 m ·...
Page 296 All manuals and user guides at all-guides.com CARBURETOR 7. Install: Spring 1 Joint collar 2 To throttle shaft 3. NOTE: Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley. 8. Install: Throttle shaft assembly 1 Washer (metal) 2 Washer (resin) 3...
Page 297 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE 7. Montieren: Installer: Installare: Ressort 1 Feder 1 Molla 1 Manchette de joint 2 Verbindungsmuffe 2 Collarino giunto 2 A l’axe de papillon 3. (zur Drosselwelle 3) All’albero della valvola a far- falla 3.
Page 298 All manuals and user guides at all-guides.com CARBURETOR 10. Install: Starter jet 1 Pilot jet 2 Spacer 3 Needle jet 4 Main jet 5 11. Install: Valve seat Screw (valve seat) 1 Needle valve 2 Float 3 Float pin 4 NOTE: After installing the needle valve to the float, install them to the carburetor.
Page 299 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE 10. Montieren: 10. Monter: 10. Installare: Gicleur de starter 1 Choke-Düse 1 Getto dell’avviamento 1 Gicleur de ralenti 2 Leerlaufdüse 2 Getto del minimo 2 Entretoise 3 Distanzstück 3 Distanziatore 3 Puits d’aiguille 4 Nadeldüse 4 Getto a spillo 4...
Page 300 All manuals and user guides at all-guides.com CARBURETOR 14. Install: Diaphragm (air cut valve) 1 Spring (air cut valve) 2 O-ring 3 Air cut valve cover 4 Screw (air cut valve cover) 5 15. Install: Diaphragm (accelerator pump) 1 Spring 2 O-ring 3 Accelerator pump cover 4 Bolt (accelerator pump cover) 5...
Page 301 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE 14. Montieren: 14. Monter: 14. Installare: Membran (Luftabschaltven- Membrane (clapet de coupure Membrana (valvola di interru- d’air) 1 til) 1 zione dell’aria) 1 Feder 2 Ressort (clapet de coupure Molla (valvola di interruzione d’air) 2 O-Ring 3 dell’aria) 2...
Page 302 All manuals and user guides at all-guides.com CARBURETOR 19. Install: Carburetor breather hose 1 NOTE: Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where they are installed. Carburetor installation 1. Install: Clamp 1 NOTE: Install the projections a on the carburetor joint between the clamp ends.
Page 303 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE 19. Montieren: 19. Monter: 19. Installare: Vergaser-Entlüftungs- Sfiatatoio carburatore 1 Durit de mise à l’air de carbu- rateur 1 schlauch 1 NOTA: HINWEIS: Collegare lo sfiatatoio del carburatore al N.B.: Die Vergaserlüfterschläuche am Ver- Installer la durit de mise à...
Page 304 All manuals and user guides at all-guides.com CARBURETOR 5. Install: Throttle cable cap 1 6. Install: Throttle cable 1 7. Adjust: Throttle grip free play Refer to “THROTTLE CABLE ADJUST- MENT” section in the CHAPTER 3. 8. Install: Throttle cable cover 1 Screw (throttle cable cover) 2 4 Nm (0.4 m ·...
Page 305 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURATORE 5. Montieren: Monter: Installare: Gasseilzugkappe 1 Tappo del cavo acceleratore 1 Cache du logement des câbles des gaz 1 Monter: 6. Montieren: Installare: Câble de gaz 1 Gaszug 1 Cavo acceleratore 1 Régler: 7.
Page 306 All manuals and user guides at all-guides.com CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER Extent of removal: 1 Cylinder head cover removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
Page 307 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ALBERI A CAMME ARBRES A CAMES COUVRE-CULASSE Organisation de la dépose: 1 Dépose du couvercle de culasse Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA CULASSE Préparation à...
Page 308 All manuals and user guides at all-guides.com CAMSHAFTS CAMSHAFTS Extent of removal: 1 Camshaft removal Extent of removal Order Part name Q’ty Remarks CAMSHAFTS REMOVAL Timing mark accessing screw Crankshaft end accessing screw Timing chain tensioner cap bolt Timing chain tensioner Refer to “REMOVAL POINTS”.
Page 309 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ALBERI A CAMME ARBRES A CAMES 1 Dépose de l’arbre à cames Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE L’ARBRE A CAMES Vis d’accès du repère de distribution Vis d’accès de l’extrémité...
Page 310 All manuals and user guides at all-guides.com CAMSHAFTS REMOVAL POINTS Camshaft 1. Remove: Timing mark accessing screw 1 Crankshaft end accessing screw 2 2. Align: T.D.C. mark With align mark. Checking steps: Turn the crankshaft counterclockwise with a wrench. NOTE: Squeezing the decompression lever allows the crankshaft to be turned easily.
Page 311 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ALBERI A CAMME AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Nockenwelle Arbre à cames Albero a camme 1. Demontieren: Déposer: Rimuovere: Bouchon de distribution 1 Schwungrad-Abdeckschrau- Vite di accesso al riferimento Bouchon droit 2 be 1 per fasatura 1...
Page 312 All manuals and user guides at all-guides.com CAMSHAFTS 5. Remove: Exhaust camshaft 1 Intake camshaft 2 NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. INSPECTION Camshaft 1. Inspect: Cam lobe Pitting/scratches/blue discoloration → Replace.
Page 313 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ALBERI A CAMME 5. Demontieren: Déposer: Rimuovere: Auslaß-Nockenwelle 1 Albero a camme di scarico 1 Arbre à cames d’échappement Einlaß-Nockenwelle 2 Albero a camme di aspirazione Arbre à cames d’admission 2 HINWEIS: Die Steuerkette mit einem Draht 3 N.B.:...
Page 314 All manuals and user guides at all-guides.com CAMSHAFTS 4. Measure: Camshaft-to-cap clearance Out of specification → Measure bearing diameter (camshaft) Camshaft-to-cap clearance: 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: Install the camshaft onto the cylinder head.
Page 315 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ALBERI A CAMME 4. Messen: Mesurer: Misurare: Nockenwellen-Lagerspiel Jeu entre arbre à cames et cha- Gioco albero a camme-cap- Unvorschriftsmäßig → Nok- peau pello Hors spécifications → Mesu- Fuori specifica → Misurare il kenwellenlagerzapfen- Durchmesser messen.
Page 316 All manuals and user guides at all-guides.com CAMSHAFTS Timing chain tensioner 1. Check: While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise. When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly.
Page 317 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Steuerkettenspanner Tendeur de la chaîne de distribution Tenditore catena di distribuzione 1. Kontrollieren: Contrôler: Controllare: Steuerkettenspanner- Tout en comprimant légère- Premendo leggermente l’asta kopf leicht mit dem Finger ment la tige du tendeur à...
Page 318 All manuals and user guides at all-guides.com CAMSHAFTS CAUTION: Do not turn the crankshaft during the camshaft installation. Damage improper valve timing will result. Install the clips, camshaft caps 4 and bolts (camshaft cap) 5. Bolt (camshaft cap): 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Before removing the clips, cover the cylin- der head with a clean rag to prevent the...
Page 319 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ALBERI A CAMME ACHTUNG: ATTENTION: ATTENZIONE: Ne pas faire tourner le vilebrequin Um Beschädigung und falsche ruotare l’albero motore pendant la mise en place des arbres Ventilsteuerzeiten zu vermei- durante l’installazione dell’albero à...
Page 320 Cylinder head cover 3 Bolt (cylinder head cover) 4 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the sealant on the cylinder head cover gasket. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 4 - 27...
Page 321 NOTA: Applicare il materiale di tenuta sulla ® Quick gasket ® Quick gasket guarnizione del coperchio della testata ACC-QUICK-GS-KT ACC-QUICK-GS-KT del cilindro. Yamaha Bond n˚ 1215: Yamaha-Dichtmasse Nr. 1215 90890-85505 90890-85505 Quick gasket ® ACC-QUICK-GS-KT YAMAHA Bond n. 1215 90890-85505...
Page 322 All manuals and user guides at all-guides.com CAMSHAFTS 7. Install: Oil tank breather hose Cylinder head breather hose Spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb) 4 - 28...
Page 323 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ALBERI A CAMME 7. Montieren: Monter: Installare: Öltank-Belüftungsschlauch Durit de mise à l’air de réser- Sfiatatoio serbatoio dell’olio Zylinderkopf-Entlüftungs- voir d’huile Sfiatatoio testata del cilindro schlauch Durit de mise à l’air de culasse Candela d’accensione Zündkerze Bougie...
Page 324 All manuals and user guides at all-guides.com CYLINDER HEAD CYLINDER HEAD Extent of removal: 1 Cylinder head removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
Page 325 All manuals and user guides at all-guides.com CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO CULASSE 1 Dépose de la culasse Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA CULASSE ET DU CYLIN- Préparation à la dépose Selle et réservoir de carburant Se reporter à...
Page 326 All manuals and user guides at all-guides.com CYLINDER HEAD INSPECTION Cylinder head 1. Eliminate: Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid dam- aging or scratching: Spark plug threads Valve seats 2.
Page 327 All manuals and user guides at all-guides.com CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO PRÜFUNG CONTROLE ISPEZIONE Zylinderkopf Culasse Testata del cilindro 1. Entfernen: Eliminer: Eliminare: Ölkohleablagerungen (im Dépôt de calamine Depositi carboniosi (dalle Brennraum) (de la chambre de combustion) camere di combustione) Einen abgerundeten Scha- Utiliser un grattoir arrondi.
Page 328 All manuals and user guides at all-guides.com CYLINDER HEAD ASSEMBLY AND INSTALLATION Cylinder head 1. Install: Decompression shaft 1 Copper washer 2 Bolt (decompression shaft) 3 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the engine oil on the decompression shaft.
Page 329 All manuals and user guides at all-guides.com CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAGGIO INSTALLA- Zylinderkopf Culasse ZIONE 1. Montieren: Monter: Testata del cilindro Axe de décompression 1 Dekompressionswelle 1 Installare: Rondelle en cuivre 2 Kupferunterlegscheibe 2 Albero di decompressione 1 Rondella di rame 2...
Page 330 All manuals and user guides at all-guides.com CYLINDER HEAD 3. Install: Washer 1 Cable guide 2 Bolts [L=145 mm (5.71 in)] 3 38 Nm (3.8 m · kg, 27 ft · lb) Bolts [L=135 mm (5.31 in)] 4 38 Nm (3.8 m · kg, 27 ft · lb) Nuts 5 10 Nm (1.0 m ·...
Page 331 All manuals and user guides at all-guides.com CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO 3. Montieren: Monter: Installare: Rondelle 1 Unterlegscheibe 1 Rondella 1 Guide de câble 2 Seilzugführng 2 Guida cavo 2 Schrauben [L = 145 mm] 3 Boulons Bulloni [L = 145 mm (5,71 in)] [L = 145 mm (5,71 in)] 3 38 Nm (3,8 m ·...
Page 332 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Extent of removal: 1 Valve removal Extent of removal Order Part name Q’ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Valve lifter Use special tool.
Page 333 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE SOUPAPES ET RESSORTS DE SOUPAPE 1 Dépose des soupapes Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté...
Page 334 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS REMOVAL POINTS Valve lifter and valve cotter 1. Remove: Valve lifter 1 Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place.
Page 335 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Tassenstößel und Ventikeile Poussoir de soupape et clavette de sou- Alzavalvola e semiconi 1. Demontieren: pape Rimuovere: Tassenstößel 1...
Page 336 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS INSPECTION Valve 1. Measure: Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)
Page 337 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE PRÜFUNG CONTROLE ISPEZIONE Ventil Soupape Valvola 1. Messen: Mesurer: Misurare: Ventilschaftspiel Jeu de queue dans le guide Gioco stelo-guida Ventilschaftspiel = Gioco stelo-guida = Jeu de queue dans le guide de sou- Ventilführungsdurchmesser...
Page 338 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS Valve guide remover: Intake 4.0 mm (0.16 in) YM-4111/90890-04111 Exhaust 4.5 mm (0.18 in) YM-4116/90890-04116 Valve guide installer: Intake 4.0 mm (0.16 in) YM-4112/90890-04112 Exhaust 4.5 mm (0.18 in) YM-4117/90890-04117 Valve guide reamer: Intake 4.0 mm (0.16 in)
Page 339 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Outil de dépose de guide Ventilführungs-Austrei- Estrattore guidavalvola: de soupape: Aspirazione 4,0 mm Einlaß 4,0 mm Admission 4,0 mm (0,16 in) (0,16 in) YM-4111/ YM-4111/90890-04111...
Page 340 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS 5. Measure: Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.0004 in) NOTE: When installing a new valve always replace the guide. If the valve is removed or replaced always replace the oil seal.
Page 341 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE 5. Messen: Mesurer: Misurare: Ventilschaftschlag Ovalisation (queue de soupape) Disassamento (stelo valvola): Hors spécifications → Rempla- Unvorschriftsmäßig → Fuori specifica → Sostituire. Erneuern.
Page 342 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS 9. Lap: Valve face Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: Apply a coarse lapping compound to the valve face.
Page 343 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE 9. Einschleifen: Roder: Lappare: Ventilteller Face de soupape Faccia della valvola Ventilsitz Siège de soupape Sede della valvola HINWEIS: N.B.: NOTA: Nach Bearbeitung des Ventilsitzes Après le surfaçage du siège de soupape Dopo aver rettificato la sede della val-...
Page 344 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS Valve spring 1. Measure: Valve spring free length a Out of specification → Replace. Free length (valve spring): Intake: 37.81 mm (1.49 in) <Limit>: 35.9 mm (1.41 in) Exhaust: 37.54 mm (1.48 in) <Limit>: 35.7 mm (1.41 in) 2.
Page 345 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Ventilfeder Ressort de soupape Molla valvola 1. Messen: Mesurer: Misurare: Ventilfederlänge (ent- Longueur libre du ressort de Lunghezza libera della molla soupape a spannt) a della valvola a...
Page 346 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS Combination of cylinder head and valve lifter 1. Combination: For this combination, match the paint color on the cylinder head with that on the valve lifter according to the chart below. Combination Valve lifter mark b Cylinder head mark...
Page 347 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Kombination von Zylinderkopf Combinaisons de culasse et de pous- Combinazione di testata del cilindro e und Ventilheber soir de soupape alzavalvola 1.
Page 348 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS 3. Install: Valve cotter NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters. Valve spring compressor: YM-04019/90890-04019 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.
Page 349 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE 3. Montieren: Monter: Installare: Ventilkeile Clavette de soupape Semiconi HINWEIS: N.B.: NOTA: Die Ventilfeder mit Ventilfederspan- Installer les clavettes de soupape tout en Comprimendo la molla della valvola con ner 1 und Halterung zusammen- un apposito compressore 1 installare i...
Page 350 All manuals and user guides at all-guides.com CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: 1 Cylinder removal 2 Piston removal Extent of removal Order Part name Q’ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Bolt (cylinder) Cylinder Piston pin clip...
Page 351 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE CYLINDRE ET PISTON 1 Dépose du cylindre 2 Dépose du piston Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DES CYLINDRES ET DES PIS- TONS...
Page 352 All manuals and user guides at all-guides.com CYLINDER AND PISTON REMOVAL POINTS Piston and piston ring 1. Remove: Piston pin clip 1 Piston pin 2 Piston 3 NOTE: Put identification marks on each piston head for reference during reinstallation. Before removing each piston pin, deburr the clip groove and pin hole area.
Page 353 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Kolben und Kolbenring Piston et segment de piston Pistone e fascia elastica 1. Demontieren: Déposer: Rimuovere: Agrafe d’axe de piston 1 Kolbenbolzen-Sicherungs- Morsetto spinotto 1 Axe de piston 2...
Page 354 All manuals and user guides at all-guides.com CYLINDER AND PISTON 77.00 ~ 77.01 mm Cylinder bore “C” (3.0315 ~ 3.0319 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = Maximum D “T”...
Page 355 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE 77,00 à Zylinderboh- 77,00– Alesaggio cilin- 77,00 ~ 77,01 mm Alésage de cylin- 77,01 mm rung “C” 77,01 mm dro “C” (3,0315 ~ 3,0319 in) dre “C”...
Page 356 All manuals and user guides at all-guides.com CYLINDER AND PISTON Piston ring 1. Measure: Ring side clearance Use a feeler gauge 1. Out of specification → Replace the pis- ton and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance.
Page 357 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Kolbenring Segment de piston Fascia elastica 1. Messen: Mesurer: Misurare: Ringnutspiel Jeu latéral du segment Gioco laterale della fascia Fühlerlehre 1 verwenden. Utilizzare uno spessimetro 1. Utiliser une jauge d’épaisseur Unvorschriftsmäßig →...
Page 358 All manuals and user guides at all-guides.com CYLINDER AND PISTON Piston pin 1. Inspect: Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: Piston pin-to-piston clearance Measurement steps: Measure the outside diameter (piston pin) If out of specification, replace the piston pin.
Page 359 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Kolbenbolzen Axe de piston Spinotto 1. Kontrollieren: Contrôler: Ispezionare: Kolbenbolzen Axe de piston Spinotto Décoloration bleue/gorges → Blaufärbung/Riefen → Sbiadimento blu/scanalature → Erneuern und Schmiersy- Remplacer puis examiner le Sostituire quindi ispezionare il stem überprüfen.
Page 360 All manuals and user guides at all-guides.com CYLINDER AND PISTON 2. Position: Top ring 2nd ring Oil ring 45° Offset the piston ring end gaps as 135° 135° shown. a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) 3.
Page 361 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE 2. Montieren: Positionner: Posizione: Segment de feu 1. Kompressionsring (Topring) Fascia superiore Segment d’étanchéité 2. Kompressionsring Seconda fascia Segment racleur d’huile Ölabstreifring Fascia raschiaolio Décaler les becs de segment Ringstöße laut Abbildung ver- Decentrare le luci delle estre-...
Page 362 All manuals and user guides at all-guides.com CYLINDER AND PISTON 3. Install: Cylinder gasket 1 Cylinder 2 NOTE: Install the cylinder with one hand while com- pressing the piston rings with the other hand. CAUTION: Pass the timing chain 3 through the tim- ing chain cavity.
Page 363 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE 3. Montieren: Monter: Installare: Joint de cylindre 1 Dichtung 1 Guarnizione cilindro 1 Cylindre 2 Zylinder 2 Cilindro 2 HINWEIS: N.B.: NOTA: Den Zylinder mit einer Hand einbau- Installer le cylindre d’une main tout en Installare il cilindro con una mano com- en, mit der anderen die Kolbenringe...
Page 364 All manuals and user guides at all-guides.com CLUTCH EC4A0000 CLUTCH Extent of removal: 1 Push rod 1, 2 and push lever shaft removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Primary driven gear removal Extent of removal Order Part name...
Page 365 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG FRIZIONE EMBRAYAGE 1 Dépose des tiges de commande 1 er 2 et du levier de poussée 2 Démontage de la tige de commande 1 Organisation de la dépose: 3 Dépose du disque de friction et du disque d’embrayage 4 Dépose du pignon mené...
Page 366 All manuals and user guides at all-guides.com CLUTCH Extent of removal Order Part name Q’ty Remarks Friction plate Clutch plate Cushion spring Seat plate Nut (clutch boss) Use special tool. Look washer Refer to “REMOVAL POINTS”. Clutch boss Thrust washer Primary driven gear Push lever shaft 4 - 50...
Page 367 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG FRIZIONE Organisation de la dépose Ordre Nom de pièce Qté Remarques Disque de friction Disque d’embrayage Ressort amortisseur Plaque d’assise Ecrou (noix d’embrayage) Utiliser un outil spécial. Rondelle d’arrêt Se reporter à “POINTS DE DEPOSE”. Noix d’embrayage Rondelle de butée Pignon mené...
Page 368 All manuals and user guides at all-guides.com CLUTCH EC4A3000 REMOVAL POINTS Clutch boss 1. Remove: Nut 1 Lock washer 2 Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. Å...
Page 369 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG FRIZIONE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Kupplungsnabe Noix d’embrayage Mozzo frizione 1. Demontieren: Déposer: Rimuovere: Ecrou 1 Mutter 1 Dado 1 Rondelle-frein 2 Sicherungsscheibe 2 Rondella di bloccaggio 2 Noix d’embrayage 3 Kupplungsnabe 3 Mozzo frizione 3...
Page 370 All manuals and user guides at all-guides.com CLUTCH Friction plate 1. Measure: Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness: 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) <Limit>: 2.7 mm (0.106 in) EC484600 Clutch plate...
Page 371 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG FRIZIONE Reibscheiben Disque de friction Disco conduttore 1. Messen: Mesurer: Misurare: Reibscheibenstärke Epaisseur de disque de friction Spessore del disco conduttore Hors-spécification → Changer Unvorschriftsmäßig → Die Fuori specifica → Sostituire in Reibscheiben Satz tous les disques de friction.
Page 372 All manuals and user guides at all-guides.com CLUTCH EC4A5000 ASSEMBLY AND INSTALLATION Push lever shaft 1. Install: Push lever shaft 1 Bolt (push lever shaft) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the lithium soap base grease on the oil seal lip.
Page 373 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG FRIZIONE ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAGGIO ED INSTALLA- Druckhebel Levier de poussée ZIONE 1. Montieren: Monter: Alberino della leva spingente Arbre de levier de poussée 1 Druckhebelwelle 1 Installare: Schraube (Druckhebelwel- Boulon (arbre de levier de Alberino della leva spingente...
Page 374 All manuals and user guides at all-guides.com CLUTCH 3. Bend the lock washer 1 tab. 4. Install: Seat plate 1 Cushion spring 2 NOTE: Install the seat plate with its chamfered por- tion a facing the clutch boss 3. Install the cushion spring with the paint b facing out.
Page 375 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG FRIZIONE 3. Die Lasche der Sicherungs- Courber la languette de la ron- Piegare la linguetta della ron- delle-frein 1. scheibe 1 umbiegen. della di bloccaggio 1. Monter: 4. Montieren: Installare: Ressort amortisseur 1 Polsterfeder 1 Molla cuscinetto 1 Plaque d’assise 2...
Page 376 All manuals and user guides at all-guides.com CLUTCH 7. Install: Push rod 2 1 Ball 2 Push rod 1 3 NOTE: Apply the engine oil on the push rod 1, 2 and ball. 8. Install: Pressure plate 1 9. Install: Clutch spring 1 Bolt (clutch spring) 2 8 Nm (0.8 m ·...
Page 377 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG FRIZIONE 7. Montieren: Monter: Installare: Tige de poussée 2 1 Druckstange 2 1 Asta di punteria 2 1 Bille 2 Kugel 2 Sfera 2 Tige de poussée 1 3 Druckstange 1 3 Asta di punteria 1 3 HINWEIS: N.B.:...
Page 378 All manuals and user guides at all-guides.com OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal: 1 Oil filter element removal 2 Water pump removal 3 Right crankcase cover removal Extent of removal Order Part name...
Page 379 All manuals and user guides at all-guides.com ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT 1 Dépose de l’élément de filtre à...
Page 380 All manuals and user guides at all-guides.com OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal Order Part name Q’ty Remarks Water pump housing Oil delivery pipe Bolt (oil hose) Kickstarter crank Right crankcase cover Impeller Washer Impeller shaft Refer to “REMOVAL POINTS”.
Page 381 All manuals and user guides at all-guides.com ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Organisation de la dépose Ordre Nom de pièce Qté...
Page 382 All manuals and user guides at all-guides.com OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER REMOVAL POINTS Impeller shaft 1. Remove: Impeller 1 Washer 2 Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller.
Page 383 All manuals and user guides at all-guides.com ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Flügelradwelle Arbre de rotor Albero girante 1.
Page 384 All manuals and user guides at all-guides.com OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER EC444200 Impeller shaft 1. Inspect: Impeller shaft 1 Bend/wear/damage → Replace. Fur deposits → Clean. EC444300 Impeller shaft gear 1. Inspect: Gear teeth a Wear/damage →...
Page 385 All manuals and user guides at all-guides.com ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Flügelradwelle Arbre de rotor Albero girante 1. Kontrollieren: Contrôler: Ispezionare: Arbre de rotor 1...
Page 386 All manuals and user guides at all-guides.com OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 2. Install: Bearing 1 NOTE: Install the bearing by pressing its outer race parallel. Impeller shaft 1. Install: Impeller shaft 1 Washer 2 Impeller 3 14 Nm (1.4 m ·...
Page 387 All manuals and user guides at all-guides.com ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO 2. Montieren: Monter: Installare: Roulement 1 Lager 1 Cuscinetto 1 HINWEIS: N.B.:...
Page 388 All manuals and user guides at all-guides.com OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 2. Install: Right crankcase cover 1 Bolt (right crankcase cover) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the engine oil on the impeller shaft end.
Page 389 All manuals and user guides at all-guides.com ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO 2. Montieren: Monter: Installare: Demi-carter droit 1 Rechten Kurbelgehäuse- Coperchio carter destro 1 Boulon (demi-carter droit) 2...
Page 390 All manuals and user guides at all-guides.com OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Water pump housing 1. Install: Dowel pin 1 O-ring 2 NOTE: Apply the lithium soap base grease on the O- ring. 2. Install: Water pump housing 1 Bolt (water pump housing) 2 10 Nm (1.0 m ·...
Page 391 All manuals and user guides at all-guides.com ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Wasserpumpengehäuse Logement de la pompe à eau Alloggiamento della pompa dell’acqua 1.
Page 392 All manuals and user guides at all-guides.com BALANCER BALANCER Extent of removal: 1 Balancer shaft drive gear 2 Balancer shaft Extent of removal Order Part name Q’ty Remarks BALANCER REMOVAL Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK-...
Page 393 All manuals and user guides at all-guides.com BALANCIER AUSGLEICHSWELLE BILANCIERE BALANCIER Organisation de la dépose: 1 Pignon mené du balancier 2 Balancier Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU BALANCIER Préparation à la dépose Pignon menant primaire Se reporter à...
Page 394 All manuals and user guides at all-guides.com BALANCER REMOVAL POINTS Balancer shaft drive gear and balancer shaft driven gear 1. Straighten the lock washer tab. 2. Loosen: Nut (primary drive gear) 1 Nut (balancer shaft driven gear) 2 NOTE: Place an aluminum plate a between the teeth of the balancer shaft drive gear 3 and driven gear 4.
Page 395 All manuals and user guides at all-guides.com BALANCIER AUSGLEICHSWELLE BILANCIERE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Ausgleichswellen-Antriebs- und - Pignon menant et pignon mené du Ingranaggio conduttore dell’albero di Abtriebsräder balancier equilibratura e ingranaggio condotto 1. Die Lasche der Sicherungs- Redresser l’ongle de rondelle dell’albero di equilibratura scheibe umbiegen.
Page 396 All manuals and user guides at all-guides.com BALANCER ASSEMBLY AND INSTALLATION Balancer shaft, balancer shaft drive gear and balancer shaft driven gear 1. Install: Balancer shaft 1 NOTE: Apply the engine oil on the bearing. When installing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crank- shaft and balancer shaft.
Page 397 All manuals and user guides at all-guides.com BALANCIER AUSGLEICHSWELLE BILANCIERE ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET INSTALLA- MONTAGGIO ED INSTALLAZIONE Ausgleichswelle, An- und TION Albero di equilibratura, ingranaggio Abtriebsrad Balancier, pignon menant de balan- conduttore dell’albero di equilibra- 1. Montieren: cier et pignon mené de balancier tura e ingranaggio condotto Ausgleichswelle 1 Monter:...
Page 398 All manuals and user guides at all-guides.com OIL PUMP OIL PUMP Extent of removal: 1 Oil pump removal 2 Oil pump disassembly Extent of removal Order Part name Q’ty Remarks OIL PUMP REMOVAL AND DIS- ASSEMBLY Preparation for removal Primary driven gear Refer to “CLUTCH”...
Page 399 All manuals and user guides at all-guides.com POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO POMPE A HUILE 1 Dépose de la pompe à huile 2 Démontage de la pompe à huile Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté...
Page 400 All manuals and user guides at all-guides.com OIL PUMP Extent of removal Order Part name Q’ty Remarks Dowel pin Washer Oil pump drive shaft Rotor housing 4 - 67...
Page 401 All manuals and user guides at all-guides.com POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO Organisation de la dépose Ordre Nom de pièce Qté Remarques Goupille Rondelle Arbre de transmission de la pompe à huile Logement de rotor Reihen- Demontage-Arbeiten Bauteil Anz. Bemerkungen folge Paßstift...
Page 402 All manuals and user guides at all-guides.com OIL PUMP INSPECTION Oil pump 1. Inspect: Oil pump drive gear 1 Oil pump drive shaft 2 Rotor housing 3 Oil pump cover 4 Cracks/wear/damage → Replace. 2. Measure: Tip clearance a (between the inner rotor 1 and outer rotor 2) Side clearance b (between the outer rotor 2 and rotor...
Page 403 All manuals and user guides at all-guides.com POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO PRÜFUNG CONTROLE ISPEZIONE Ölpumpe Pompe à huile Pompa dell’olio 1. Kontrollieren: Contrôler: Ispezionare: Ölpumpen-Antriebsrad 1 Pignon menant de pompe à Ingranaggio conduttore della huile 1 Ölpumpen-Antriebswelle 2 pompa dell’olio 1 Rotorgehäuse 3 Arbre menant de pompe à...
Page 404 All manuals and user guides at all-guides.com OIL PUMP ASSEMBLY AND INSTALLATION Oil pump 1. Install: Oil pump drive shaft 1 Washer 2 Dowel pin 3 Inner rotor 1 4 NOTE: Apply the engine oil on the oil pump drive shaft and inner rotor 1.
Page 405 All manuals and user guides at all-guides.com POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET INSTALLA- MONTAGGIO ED INSTALLA- Ölpumpe TION ZIONE 1. Montieren: Pompe à huile Pompa dell’olio Ölpumpen-Antriebswelle 1 Installer: Installare: Beilagscheibe 2 Arbre de transmission de la Albero comando della...
Page 406 All manuals and user guides at all-guides.com OIL PUMP 4. Install: Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt (oil pump assembly) [L = 25 mm (0.94 in)] 4 10 Nm (1.0 m · kg, 7.2 ft · lb) Bolt (oil pump assembly) [L = 30 mm (1.18 in)] 5 10 Nm (1.0 m ·...
Page 407 All manuals and user guides at all-guides.com POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO 4. Montieren: Monteur: Installare: Rotor extérieur 2 1 Außenrotor 2 1 Rotore esterno 2 1 Goupille de serrage 2 Paßstift 2 Perno di centraggio 2 Essemble pompe à huile 3 Ölpumpe 3 Gruppo pompa dell’olio 3 Schraube (Ölpumpe)
Page 408 All manuals and user guides at all-guides.com KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT Extent of removal: 1 Kick shaft removal 2 Kick shaft disassembly 3 Shift shaft removal 4 Segment removal Extent of removal Order Part name Q’ty Remarks KICK SHAFT AND SHIFT...
Page 409 All manuals and user guides at all-guides.com ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO ARBRE DE KICK ET ARBRE DE SELECTEUR 1 Dépose de l’arbre de kick 2 Démontage de l’arbre de kick Organisation de la dépose: 3 Dépose arbre de sélecteur 4 Dépose de segment...
Page 410 All manuals and user guides at all-guides.com KICK SHAFT AND SHIFT SHAFT Extent of removal Order Part name Q’ty Remarks Torsion spring Roller Shift guide Refer to “REMOVAL POINTS”. Shift lever assembly Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment...
Page 411 All manuals and user guides at all-guides.com ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Organisation de la dépose Ordre Nom de pièce Qté Remarques Ressort de torsion Rouleau Guide de sélecteur Se reporter à...
Page 412 All manuals and user guides at all-guides.com KICK SHAFT AND SHIFT SHAFT REMOVAL POINTS Kick shaft assembly 1. Remove: Kick shaft assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1.
Page 413 All manuals and user guides at all-guides.com ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Kickstarterwelle (komplett) Arbre de kick complet Gruppo albero pedivella 1. Demontieren: Déposer: Rimuovere: Arbre de kick complet 1...
Page 414 All manuals and user guides at all-guides.com KICK SHAFT AND SHIFT SHAFT EC4B4400 Shift shaft 1. Inspect: Shift shaft 1 Bend/damage → Replace. Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4...
Page 415 All manuals and user guides at all-guides.com ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Schaltwelle Arbre de sélecteur Albero del cambio 1. Kontrollieren: Contrôler: Ispezionare: Arbre de sélecteur 1 Schaltwelle 1 Albero del cambio 1 Tordu/endommagement →...
Page 416 All manuals and user guides at all-guides.com KICK SHAFT AND SHIFT SHAFT EC4B5111 Stopper lever 1. Install: Torsion spring 1 Stopper lever 2 Bolt (stopper lever) 3 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Align the stopper lever roller with the slot on segment.
Page 417 All manuals and user guides at all-guides.com ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Rastenhebel Levier de butée Leva di arresto 1. Montieren: Monter: Installare: Ressort de torsion 1 Torsionsfeder 1 Molla di torsione 1 Levier de butée 2 Rastenhebel 2...
Page 418 All manuals and user guides at all-guides.com KICK SHAFT AND SHIFT SHAFT 4. Install: Bolt (shift guide) 1 10 Nm (1.0 m · kg, 7.2 ft · lb) Shift shaft 1. Install: Roller 1 Collar 2 Torsion spring 3 Shift shaft 4 NOTE: Apply the engine oil on the roller and shift shaft.
Page 419 All manuals and user guides at all-guides.com ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO 4. Montieren: Monter: Installare: Boulon (guide de sélecteur) 1 Schraube (Schaltklinke) 1 Bullone (guida cambio) 1 10 Nm (1,0 m · kg) 10 Nm (1,0 m ·...
Page 420 All manuals and user guides at all-guides.com KICK SHAFT AND SHIFT SHAFT 2. Install: Torsion spring 1 To kick shaft 2. NOTE: Make sure the stopper a of the torsion spring fits into the hole b on the kick shaft. 3.
Page 421 All manuals and user guides at all-guides.com ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO 2. Montieren: Monter: Installare: Ressort de torsion 1 Torsionfeder 1 Molla di torsione 1 Sur l’arbre de kick 2. (an der Kickstarterwelle 2) All’albero pedivella 2.
Page 422 All manuals and user guides at all-guides.com CDI MAGNETO EC4L0000 CDI MAGNETO Extent of removal: 1 CDI magneto removal Extent of removal Order Part name Q’ty Remarks CDI MAGNETO REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
Page 423 All manuals and user guides at all-guides.com VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI VOLANT MAGNETIQUE CDI 1 Dépose du volant magnétique CDI Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE CDI Préparation à la dépose Selle et réservoir de carburant Se reporter à...
Page 424 All manuals and user guides at all-guides.com CDI MAGNETO EC4L3000 REMOVAL POINTS Rotor 1. Remove: Nut (rotor) 1 Washer 2 Use the rotor holding tool 3. Rotor holding tool: YU-1235/90890-01235 2. Remove: Rotor 1 Use the flywheel puller 2. Flywheel puller: YU-33270-B/90890-01362 NOTE: Install three bolts 3 of the proper size, as...
Page 425 All manuals and user guides at all-guides.com VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Rotor Rotor Rotore 1. Demontieren: Déposer: Rimuovere: Ecrou (rotor) 1 Mutter (Rotor) 1 Dado (rotore) 1 Rondelle 2 Beilagscheibe 2 Rondella 2 Den Rotorhalter 3 verwen- Utiliser l’outil de maintien de...
Page 426 Apply the sealant on the grommet of the CDI magneto lead. Tighten the screws using the T30 bit. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 2. Install: Woodruff key 1 Rotor 2 NOTE: Clean the tapered portions of the crankshaft and rotor.
Page 427 ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond n˚1215: ® Quick gasket Quick gasket ® 90890-85505 ACC-QUICK-GS-KT ACC-QUICK-GS-KT YAMAHA Bond n. 1215: YAMAHA-Dichtmasse 90890-85505 Nr. 1215 90890-85505 Monter: 2. Montieren: Installare: Clavette de demi-lune 1 Scheibenfeder 1 Linguetta Woodruff 1 Rotor 2...
Page 428 All manuals and user guides at all-guides.com CDI MAGNETO 4. Connect: CDI magneto lead Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2. 5. Install: Dowel pin Gasket (left crankcase cover) Left crankcase cover 1 Hose guide (cylinder head breather hose) 2 Bolt (left crankcase cover) 3 10 Nm (1.0 m ·...
Page 429 All manuals and user guides at all-guides.com VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI 4. Anschließen: Connecter: Collegare: CDI-Schwungradmagnet- Fil de volant magnétique CDI Cavo magnete CDI zünder-Kabel Se référer au paragraphe “DIA- Fare riferimento al paragrafo Siehe unter “KABELFÜH- GRAMME DE CHEMINE- “SCHEMA DEL PERCORSO RUNG”...
Page 430 All manuals and user guides at all-guides.com ENGINE REMOVAL EC4M0000 ENGINE REMOVAL Extent of removal Order Part name Q’ty Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the WARNING suitable stand under the frame. Support the machine securely so there is no danger of it falling over.
Page 431 All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE DEPOSE DU MOTEUR Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU MOTEUR AVERTISSEMENT Préparation à la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas de approprié...
Page 432 All manuals and user guides at all-guides.com ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Order Part name Q’ty Remarks Spark plug cap Disconnect the CDI magneto lead. Right engine guard Neutral switch Bolt (oil hose) Drive chain sprocket cover Nut (drive sprocket) Lock washer Refer to “REMOVAL POINTS”.
Page 433 All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE 1 Dépose du moteur Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques Capuchon de bougie Déconnecter le fil du volant magnétique CDI. Protège-carter droit Contacteur de point mort Boulon (durit d’huile)
Page 434 All manuals and user guides at all-guides.com 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:...
Page 435 All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Antriebsritzel Pignon d’entraînement Corona dentata trasmissione 1. Demontieren: Déposer: Rimuovere: Mutter (Antriebsritzel) 1 Ecrou (pignon d’entraînement) Dado (corona dentata trasmis- Sicherungsscheibe 2 sione) 1 Rondelle-frein 2...
Page 436 All manuals and user guides at all-guides.com ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1. Install: Engine 1 Install the engine from right side. Pivot shaft 2 85 Nm (8.5 m · kg, 61 ft · lb) Engine mounting bolt (lower) 3 69 Nm (6.9 m ·...
Page 437 All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAGGIO INSTALLA- Motor montieren Montage du moteur ZIONE 1. Montieren: Monter: Installazione del motore Moteur 1 Motor 1 Installare: (von der rechten Seite) Motore 1 Monter le moteur par le côté...
Page 438 All manuals and user guides at all-guides.com ENGINE REMOVAL 2. Install: Lock washer 1 Nut (drive sprocket) 2 75 Nm (7.5 m · kg, 54 ft · lb) NOTE: Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4.
Page 439 All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE 2. Montieren: Monter: Installare: Rondelle-frein 1 Sicherungsscheibe 1 Rondella di bloccaggio 1 Ecrou (pignon d’entraînement) Mutter (Antriebsritzel) 2 Dado (corona dentata trasmis- sione) 2 75 Nm (7,5 m · kg) 75 Nm (7,5 m ·...
Page 440 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal: 1 Crankcase separation 2 Crankshaft removal Extent of removal Order Part name Q’ty Remarks CRANKCASE AND CRANK- SHAFT REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON”...
Page 441 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE CARTER ET VILEBREQUIN Organisation de la dépose: 1 Séparation du carter 2 Dépose du carter d’huile Organisation de la dépose Ordre Nom de pièce Qté...
Page 442 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q’ty Remarks Bolt [L = 45 mm (1.77 in)] Bolt [L = 55 mm (2.17 in)] Bolt [L = 70 mm (2.76 in)] Hose guide Refer to “REMOVAL POINTS”.
Page 443 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Organisation de la dépose Ordre Nom de pièce Qté Remarques Boulon [L = 45 mm (1,77 in)] Boulon [L = 55 mm (2,17 in)] Boulon [L = 70 mm (2,76 in)] Guide de durit Se reporter à...
Page 444 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT CRANKCASE BEARING Extent of removal: 1 Crankcase bearing removal Extent of removal Order Part name Q’ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to “TRANSMISSION, SHIFT Shift cam and shift fork CAM AND SHIFT FORK”...
Page 445 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE ROULEMENTS DE CARTER Organisation de la dépose: Dépose des roulements de carter Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DES ROULEMENTS DE CAR- Préparation à...
Page 446 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT REMOVAL POINTS Crankcase 1. Separate: Right crankcase Left crankcase Separation steps: Remove the crankcase bolts 1, hose guide 2 and clutch cable holder 3. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.
Page 447 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Kurbelgehäuse Carter Carter 1. Trennen: Séparer: Separare: Rechtes Kurbelgehäusehälf- Demi-carter droit Carter destro Demi-carter gauche Carter sinistro Linkes Kurbelgehäusehälfte Etapes de la séparation: Fasi per la separazione:...
Page 448 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT Crankshaft 1. Remove: Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 CAUTION: Do not use a hammer to drive out the crankshaft. Crankcase bearing 1. Remove: Bearing 1 NOTE: Remove the bearing from the crankcase by...
Page 449 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Kurbelwelle Vilebrequin Albero motore 1. Demontieren: Déposer: Rimuovere: Vilebrequin 1 Kurbelwelle 1 Albero motore 1 Das Kurbelgehäuse-Trenn- Utiliser l’outil de séparateur de Utilizzare l’utensile per la carter 2.
Page 450 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1. Measure: Runout limit a Small end free play limit b Connecting rod big end side clearance Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge.
Page 451 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Kurbelwelle Vilebrequin Albero motore 1. Messen: Mesurer: Misurare: Limite de faux-rond a Schlaggrenze a Limite di disassamento a Pleuel-Radialspiel b Limite gioco piede di biella b Limite de déflexion de pied de bielle b Pleuel-Axialspiel c...
Page 452 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankcase bearing 1. Install: Bearing Bearing stopper Screw (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) Screw [bearing stopper (crankshaft)] 1 10 Nm (1.0 m · kg, 7.2 ft · lb) To left and right crankcase.
Page 453 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAGGIO E INSTALLAZIONE Kurbelwellenlager Roulement de carter Cuscinetto del basamento 1. Einbauen: Installer: Installare: Roulement Lager Cuscinetto Butoir de roulement Lageranschlag Fermo cuscinetto...
Page 454 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Apply: Sealant On the right crankcase 1. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 NOTE: Clean the contacting surface of left and right crankcase before applying the sealant. 5. Install: Dowel pin 1...
Page 455 1) Quick gasket ® Quick gasket ® ACC-QUICK-GS-KT ACC-QUICK-GS-KT ® Quick gasket Yamaha Bond n˚1215: YAMAHA Bond n. 1215: ACC-QUICK-GS-KT 90890-85505 90890-85505 Yamaha-Dichtmasse Nr. 1215 90890-85505 N.B.: NOTA: Nettoyer la surface de contact des demi- Pulire la superficie di contatto dei semi- HINWEIS: carters gauche et droit avant d’appliquer...
Page 456 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT 6. Tighten: Hose guide 1 Clutch cable holder 2 Bolt (crankcase) 3 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 7.
Page 457 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE 6. Montieren: Monter: Serrare: Guide de durit 1 Kabelführung 1 Guida del flessibile 1 Kupplungszug-Halterung 2 Supporto cavo frizione 2 Support de câble d’embrayage Schraube (Kurbelgehäuse) Bullone (carter) 3 Boulon (carter) 3...
Page 458 All manuals and user guides at all-guides.com TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: 1 Shift fork, shift cam, main axle and drive axle removal Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFT CAM...
Page 459 All manuals and user guides at all-guides.com BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION Organisation de la dépose: 1 Dépose des fourchettes de sélection, du tambour, de l’arbre primaire et de l’arbre secondaire Organisation de la dépose Ordre Nom de pièce...
Page 460 All manuals and user guides at all-guides.com TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1. Remove: Main axle 1 Drive axle 2 Shift cam Shift fork 3 Shift fork 2 Shift fork 1 NOTE: Remove assembly with the collar 3 installed to the crankcase.
Page 461 All manuals and user guides at all-guides.com BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Getriebe Boîte à vitesses Trasmissione 1. Demontieren: Déposer: Rimuovere: Arbre primaire 1...
Page 462 All manuals and user guides at all-guides.com TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4810 Shift fork, shift cam and segment 1. Inspect: Shift fork 1 Wear/damage/scratches → Replace. 2. Inspect: Shift cam 1 Segment 2 Wear/damage → Replace. 3. Check: Shift fork movement Unsmooth operation →...
Page 463 All manuals and user guides at all-guides.com BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO Schaltgabeln und Schaltwalze Fourchette, tambour et barillet Forcella del cambio, camma del cam- 1.
Page 464 All manuals and user guides at all-guides.com TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: 2nd wheel gear (28T) 1 4th wheel gear (25T) 2 3rd wheel gear (28T) 3 5th wheel gear (22T) 4 1st wheel gear (31T) 5 O-ring 6 To drive axle 7.
Page 465 All manuals and user guides at all-guides.com BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO 2. Montieren: Monter: Installare: Pignon de 2ème (28D) 1 Zahnrad 2. Gang Ingranaggio a ruota per la 2a Pignon de 4ème (25D) 2 (28 Zähne) 1 (28T) 1...
Page 466 All manuals and user guides at all-guides.com TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: Shift fork 1 (L) 1 Shift fork 2 (C) 2 Shift fork 3 (R) 3 Shift cam 4 To main axle and drive axle. NOTE: Apply the molybdenum disulfide oil on the shift fork grooves.
Page 467 All manuals and user guides at all-guides.com BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO 5. Montieren: Monter: Installare: Fourchette 1 (L) 1 Schaltgabel 1 (L) 1 Forcella del cambio 1 (L) 1 Fourchette 2 (C) 2 Schaltgabel 2 (C) 2 Forcella del cambio 2 (C) 2...
Page 468 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL Extent of removal: 1 Front wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty...
Page 469 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE ROUE AVANT 1 Dépose de la roue avant 2 Dépose du roulement de roue Organisation de la dépose: 3 Dépose du disque de frein Organisation de la dépose...
Page 470 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL Extent of removal: 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks REAR WHEEL REMOVAL WARNING Preparation for removal Hold the machine by placing the...
Page 471 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE ROUE ARRIERE 1 Dépose de la roue arrière 2 Dépose du roulement de roue Organisation de la dépose: 3 Dépose du disque de frein Organisation de la dépose Ordre Nom de pièce...
Page 472 All manuals and user guides at all-guides.com 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...
Page 473 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Hinterrad Roue arrière Ruota posteriore 1. Demontieren: Déposer: Rimuovere: Roue 1 Rad 1 Ruota 1 HINWEIS: N.B.:...
Page 474 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: Wheel axle bends Out of specification → Replace. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading.
Page 475 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Radachse Axe de roue Asse della ruota 1. Messen: Mesurer: Misurare: Radachsschlag Déformation de l’axe de roue Deformazioni asse della ruota Hors-spécification →...
Page 476 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION Front wheel 1. Install: Bearing (left) 1 Spacer 2 Bearing (right) 3 Oil seal 4 NOTE: Apply the lithium soap base grease on the bearing and oil seal lip when installing.
Page 477 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAGGIO INSTALLA- Roue avant Vorderrad ZIONE Monter: 1. Montieren: Ruota anteriore Roulement (gauche) 1 Lager (links) 1 Installare: Entretoise 2...
Page 478 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL 5. Install: Wheel NOTE: Install the brake disc between the brake pads correctly. Make sure that the projections a in the trip meter gear unit fits over the stopper b on the front fork outer tube.
Page 479 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 5. Montieren: Monter: Installare: Roue Ruota HINWEIS: N.B.: NOTA: Die Bremsscheibe zwischen die Reposer correctement le disque du Installare correttamente il disco freno Bremsbeläge führen.
Page 480 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL 9. Install: Brake hose 1 10 Nm (1.0 m · kg, 7.2 ft · lb) To brake hose holder 2. NOTE: Before tightening the bolt (brake hose holder), pass the brake hose in front of the axle boss a, then fit it into the hose groove b so that the brake hose does not contact the nut (wheel...
Page 481 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 9. Montieren: Monter: Installare: Tuyau de frein 1 Bremsschlauch 1 Flessibile freno 1 10 Nm (1,0 m · kg) 10 Nm (1,0 m ·...
Page 482 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL EC5251A0 Rear wheel 1. Install: Bearing (right) 1 Circlip 2 Spacer 3 Bearing (left) 4 Oil seal 5 NOTE: Apply the lithium soap base grease on the bearing and oil seal lip when installing.
Page 483 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Hinterrad Roue arrière Ruota posteriore 1. Montieren: Monter: Installare: Roulement (droit) 1 Lager (rechts) 1 Cuscinetto (destro) 1 Circlip 2 Sicherungsring 2 Anello elastico di arresto 2 Entretoise 3...
Page 484 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL 4. Install: Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip. 5. Install: Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly.
Page 485 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 4. Montieren: Monter: Installare: Collerette 1 Hülse 1 Collarino 1 HINWEIS: N.B.: NOTA: Lithiumseifen-Schmierfett auf der Öl- Appliquer la graisse à base de savon au Applicare grasso a base di sapone di litio dichtungslippe auftragen.
Page 486 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL 9. Adjust: Drive chain slack a Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 in) Refer “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAP- TER 3. 10.
Page 487 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 9. Einstellen: Régler: Regolare: Antriebsketten-Durchhang Flèche de chaîne de transmis- Tensione della catena di tra- sion a smissione a Antriebsketten-Durch- Flèche de chaîne de trans- Tensione della catena di...
Page 488 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 2 Brake caliper removal 3 Brake master cylinder removal Extent of removal Order Part name Q’ty...
Page 489 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE FREIN AVANT ET FREIN ARRIERE FREIN AVANT Organisation de la dépose: 1 Dépose du tuyau de frein 2 Dépose de l’étrier de frein 3 Dépose du maître-cylindre de frein Organisation de la dépose Ordre...
Page 490 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE Extent of removal: 1 Brake caliper removal 2 Brake hose removal 3 Brake master cylinder removal Extent of removal Order Part name Q’ty Remarks REAR BRAKE REMOVAL WARNING Preparation for removal...
Page 491 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE FREIN ARRIERE 1 Dépose de l’étrier de frein 2 Dépose du tuyau de frein Organisation de la dépose: 3 Dépose du maître-cylindre de frein Organisation de la dépose Ordre Nom de pièce...
Page 492 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE BRAKE CALIPER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front brake caliper disassembly 2 Rear brake caliper disassembly Extent of removal Order Part name Q’ty Remarks BRAKE CALIPER DISASSEM- Pad pin...
Page 493 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE DEMONTAGE DE L’ETRIER Å Avant ı Arrière Organisation de la dépose: Démontage de l’étrier de frein avant Démontage de l’étrier de frein arrière Organisation de la dépose Ordre Nom de pièce...
Page 494 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE BRAKE MASTER CYLINDER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front brake master cylinder disassembly 2 Rear brake master cylinder disassembly Extent of removal Order Part name Q’ty Remarks...
Page 495 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE DEMONTAGE DU MAITRE-CYLINDRE DE FREIN Å Avant ı Arrière Organisation de la dépose: Démontage de l’étrier de frein avant Démontage de l’étrier de frein arrière Organisation de la dépose Ordre Nom de pièce...
Page 496 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 Å REMOVAL POINTS Brake fluid 1. Remove: [Front] Brake master cylinder cap 1 [Rear] Brake master cylinder guard 1 Reservoir tank cap 2 NOTE: Do not remove the diaphragm. ı...
Page 497 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Bremsflüssigkeit Liquide de frein Liquido dei freni 1. Demontieren: Déposer: Rimuovere: [Vorn] [Arrière] [Anteriore] Hauptbremszylinderdeckel 1 Coperchio pompa del freno 1...
Page 498 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston seal kit Å 1. Remove: Dust seal 1 Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: Never attempt to pry out piston seals and ı...
Page 499 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Bremssattelkolben-Dichtungssatz Kit de joint de piston d’étrier de frein Set guarnizioni pistoncino della pinza 1. Demontieren: Déposer: freno Joint antipoussière 1 Staubschutzring 1 Rimuovere: Joint de piston 2...
Page 500 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE Brake caliper Å ı 1. Inspect: Brake caliper cylinder inner surface a Wear/score marks → Replace brake caliper assembly. Å Front ı Rear 2. Inspect: Brake caliper piston 1 Wear/score marks →...
Page 501 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Bremssattel Etrier de frein Pinza del freno 1. Kontrollieren: Contrôler: Ispezionare: Hauptbremszylinder-Boh- Surface interne du maître- Superficie interna cilindro cylindre de frein a rungsfläche a pinza del freno a Usure/rayures →...
Page 502 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Å Piston seal 1 Dust seal 2 WARNING Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on brake caliper correctly.
Page 503 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE 2. Montieren: Monter: Installare: Joint de piston 1 Dichtring 1 Guarnizione dei pistoncini 1 Joint antipoussière 2 Staubschutzring 2 Guarnizione parapolvere 2 WARNUNG AVERTISSEMENT Toujours utiliser des joints de piston...
Page 504 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Copper washer 1 Union bolt 2 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe por- tion a directs as show and lightly touches the projection b on the brake caliper.
Page 505 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE 2. Montieren: Monter: Installare: Rondelle en cuivre 1 Kupferscheibe 1 Rondella di rame 1 Boulon-raccord 2 Hohlschraube 2 Vite di unione 2 30 Nm (3,0 m ·...
Page 506 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake disc cover 1 Bolt (brake disc cover) 2 7 Nm (0.7 m · kg, 5.1 ft · lb) 3. Install: Copper washer 1 Brake hose 2 Union bolt 3 30 Nm (3.0 m ·...
Page 507 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE 2. Montieren: Monter: Installare: Cache de disque de frein 1 Bremsscheiben-Abdeckung Copridisco 1 Bullone (copridisco) 2 Boulon (cache de disque de frein) 2 Schraube (Bremsscheiben- 7 Nm (0,7 m ·...
Page 508 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE Brake master cylinder kit 1. Clean: Brake master cylinder Brake master cylinder kit Clean them with brake fluid. 2. Install: ı Å Brake master cylinder cup (primary) 1 Brake master cylinder cup (secondary) To brake master cylinder piston 3.
Page 509 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Hauptbremszylindersatz Kit de maître-cylindre de frein Kit pompa del freno 1. Reinigen: Nettoyer: Pulire: Hauptbremszylinder Maître-cylindre de frein Pompa del freno Hauptbremszylindersatz Kit de maître-cylindre de frein Kit pompa del freno...
Page 510 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Å [Front] Brake master cylinder kit 1 Washer 2 Circlip 3 Brake master cylinder boot 4 To brake master cylinder 5. [Rear] Brake master cylinder kit 1 Push rod 2 Circlip 3 ı...
Page 511 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE 4. Montieren: Monter: Installare: [Vorn] [Avant] [Anteriore] Hauptbremszylindersatz 1 Set pompa del freno 1 Kit de maître-cylindre de frein Unterlegscheibe 2 Rondella 2 Rondelle ordinaire 2 Sicherungsring 3...
Page 512 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake lever 1 Bolt (brake lever) 2 6 Nm (0.6 m · kg, 4.3 ft · lb) Nut (brake lever) 3 6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting...
Page 513 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE 2. Montieren: Monter: Installare: Levier de frein 1 Bremshebel 1 Leva del freno 1 Boulon (levier de frein) 2 Schraube (Bremshebel) 2 Bullone (leva del freno) 2 6 Nm (0,6 m ·...
Page 514 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Pin 1 Washer 2 Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” sec- tion in the CHAPTER 3. Front brake hose 1.
Page 515 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE 4. Montieren: Monter: Installare: Goupille 1 Stift 1 Perno 1 Rondelle 2 Unterlegscheibe 2 Rondella 2 Goupille fendue 3 Splint 3 Copiglia 3 HINWEIS: N.B.:...
Page 516 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Copper washer 1 Brake hose 2 Union bolt 3 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that it contacts the master cylinder projection a and that...
Page 517 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE 4. Montieren: Monter: Installare: Rondelle en cuivre 1 Kupferscheibe 1 Rondella di rame 1 Durit de frein 2 Bremsschlauch 2 Flessibile freno 2 Boulon-raccord 3 Hohlschraube 3...
Page 518 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake hose holder 1 Screw (brake hose holder) 2 4 Nm (0.4 m · kg, 2.9 ft · lb) CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber).
Page 519 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE 2. Montieren: Monter: Installare: Support de tuyau de frein 1 Bremsschlauch-Halterung Supporto flessibile freno 1 Vis (support de tuyau de frein) Vite (supporto flessibile freno) Schraube (Halterung) 2 4 Nm (0,4 m ·...
Page 520 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: Brake system Refer “BRAKE SYSTEM BLEEDING” section in the CHAPTER 3. Inspect: Brake fluid level Fluid at lower level → Fill up. Refer “BRAKE FLUID LEVEL INSPECTION”...
Page 521 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE 2. Entlüften: Purger l’air: Spurgo dell’aria: Bremsanlage Circuit de freinage Sistema frenante Siehe unter “HYDRAULI- reporter à section Fare riferimento al paragrafo SCHE BREMSANLAGE “PURGE D’AIR DU CIR-...
Page 522 All manuals and user guides at all-guides.com CHAS FRONT FORK EC550000 FRONT FORK Extent of removal: 1 Front fork removal Extent of removal Order Part name Q’ty Remarks FRONT FORK REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Page 523 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE FOURCHE AVANT Organisation de la dépose: 1 Dépose de la fourche avant Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA FOURCHE AVANT AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support...
Page 524 All manuals and user guides at all-guides.com CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY Extent of removal: 1 Oil seal removal 2 Damper rod removal Extent of removal Order Part name Q’ty Remarks FRONT FORK DISASSEMBLY Front fork cap bolt Refer to “REMOVAL POINTS”.
Page 525 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE DEMONTAGE DE LA FOURCHE AVANT 1 Dépose de la bague d’étanchéité 2 Dépose de la tige d’amortisseur Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté...
Page 526 All manuals and user guides at all-guides.com CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be main- tained at the dealers. CAUTION: To prevent an accidental explosion of air, following instructions should...
Page 527 N.B.: dere Aufmerksamkeit und sollte am La fourche avant nécessite une soi- cautela. Pertanto si consiglia di affidare besten vom Yamaha-Händler gewar- gneuse attention. Il est donc recom- la manutenzione della forcella anteriore tet werden. mandé de la faire entretenir chez le ai rivenditori.
Page 528 All manuals and user guides at all-guides.com CHAS FRONT FORK EC553201 Inner tube 1. Remove: Dust seal 1 Stopper ring 2 Using slotted-head screwdriver. CAUTION: Take care not to scratch the inner tube. 2. Remove: Inner tube 1 Oil seal removal steps: Push in slowly a the inner tube just before it bottoms out and then pull it back quickly Repeat this step until the inner tube can...
Page 529 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Gleitrohr Tube interne Tubo di forza 1. Demontieren: Déposer: Rimuovere: Joint antipoussière 1 Staubschutzring 1 Guarnizione parapolvere 1 Bague d’arrêt 2 Sicherungsring 2 Anello di arresto 2 Einen Schlitzschraubendre- En utilisant un tournevis à...
Page 530 All manuals and user guides at all-guides.com CHAS FRONT FORK EC554200 Base valve 1. Inspect: Valve assembly 1 Wear/damage → Replace. O-ring 2 Damage → Replace. EC554400 Fork spring 1. Measure: Fork spring free length a Out of specification → Replace. Fork spring free length: 460 mm (18.1 in) <Limit>: 455 mm (17.9 in)
Page 531 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Luftventil Soupape de base Valvola base 1. Kontrollieren: Contrôler: Ispezionare: Ensemble clapet 1 Luftventil 1 Gruppo valvola 1 Usure/endommagement → Verschleiß/Beschädigung → Usura/danno → Sostituire. Erneuern. O-ring 2 Remplacer.
Page 532 All manuals and user guides at all-guides.com CHAS FRONT FORK Front fork cap bolt 1. Inspect: Front fork cap bolt 1 O-ring 2 Air bleed screw 3 Wear/damage → Replace. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2.
Page 533 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Telegabelverschlußschraube Bouchon de tube de fourche Vite mordente forcella anteriore 1. Kontrollieren: Contrôler: Ispezionare: Bouchon de tube de fourche 1 Telegabelverschlußschrau- Vite mordente forcella ante- Joint torique 2 be 1 riore 1 Vis de purge d’air 3...
Page 534 All manuals and user guides at all-guides.com 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.
Page 535 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 5. Montieren: Monter: Installare: Guide de ressort 1 Federsitz 1 Guida molla 1 Contre-écrou 2 Sicherungsmutter 2 Controdado 2 Sur la tige d’amortisseur 3. (am Dämpferrohr 3) Sull’asta pompante 3.
Page 536 All manuals and user guides at all-guides.com CHAS FRONT FORK 9. Install: Slide metal 1 Oil seal washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-01442/90890-01442 10.
Page 537 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 9. Montieren: Monter: Installare: Bague antifriction 1 Gleitbuchse 1 Metallo di scorrimento 1 Öldichtungsscheibe 2 Rondella paraolio 2 Rondelle de bague d’étanchéité (auf Gleitrohr-Nut) Sulla fessura del fodero. Dans l’ouverture de fourreau.
Page 538 All manuals and user guides at all-guides.com 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.
Page 539 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 13. Kontrollieren: 13. Contrôler: 13. Controllare: Leichtgängigkeit des Stand- Mouvement régulier du tube Movimento agevole del tubo di rohres Schwergängigkeit → plongeur forza Die Schritte 2 bis 12 wieder- Raideur/coincement/point dur Tenuta/resistenza/punti rugo-...
Page 540 All manuals and user guides at all-guides.com CHAS FRONT FORK 19. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level.
Page 541 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 19. Zehn Minuten warten, bis et- 19. Attendre dix minutes jusqu’à ce 19. Attendere dieci minuti finché non waige Luftbläschen sich auf- que les bulles d’air aient disparu vengono rimosse le bolle d’aria gelöst haben, bevor der Ga- de la fourche avant et que l’huile...
Page 542 All manuals and user guides at all-guides.com CHAS FRONT FORK 21. Measure: Distance a Out of specification → Turn into the locknut. Distance a: 20 mm (0.79 in) or more Between damper rod 1 top and locknut 2 top. 22. Loosen: Rebound damping adjuster 1 NOTE: Loosen the rebound damping adjuster finger...
Page 543 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 21. Messen: 21. Mesurer: 21. Misurare: Distance a Gewindelänge a Distanza a Hors spécification → Serrer le Unvorschriftsmäßig → Die Fuori specifica → Avvitare il contre-écrou. Sicherungsmutter hineindre- controdado.
Page 544 All manuals and user guides at all-guides.com CHAS FRONT FORK 26. Tighten: Front fork cap bolt (locknut) 1 29 Nm (2.9 m · kg, 21 ft · lb) NOTE: While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4.
Page 545 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 26. Festziehen: 26. Serrer: 26. Serrare: Telegabelverschlußschrau- Bouchon de tube de fourche Vite mordente forcella ante- (contre-écrou) 1 be (Sicherungsmutter) 1 riore (controdado) 1 29 Nm (2,9 m · kg) 29 Nm (2,9 m ·...
Page 546 All manuals and user guides at all-guides.com CHAS FRONT FORK 4. Tighten: Pinch bolt (upper bracket) 1 23 Nm (2.3 m · kg, 17 ft · lb) Pinch bolt (lower bracket) 2 20 Nm (2.0 m · kg, 14 ft · lb) CAUTION: Tighten the lower bracket to specified torque.
Page 547 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 4. Festziehen: Serrer: Serrare: Klemmschraube (obere Ga- Boulon de bridage (té supé- Bullone di serraggio (piastra rieur) 1 belbrücke) 1 superiore) 1 23 Nm (2,3 m · kg) 23 Nm (2,3 m ·...
Page 548 All manuals and user guides at all-guides.com CHAS HANDLEBAR EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal Headlight Decompression cable Disconnect at the lever side. Decompression lever holder Clutch cable Disconnect at the lever side.
Page 549 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANUBRIO GUIDON Organisation de la dépose: 1 Dépose du guidon Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU GUIDON Préparation pour la dépose Phare Câble de décompression Déconnecter du côté...
Page 550 All manuals and user guides at all-guides.com CHAS HANDLEBAR EC5B3000 REMOVAL POINTS Brake master cylinder 1. Remove: Brake master cylinder bracket 1 Brake master cylinder 2 CAUTION: Do not let the brake master cylinder hang on the brake hose. Keep the brake master cylinder cap side horizontal to prevent air from coming in.
Page 551 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANUBRIO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Hauptbremszylinder Maître-cylindre de frein Pompa del freno 1. Demontieren: Déposer: Rimuovere: Hauptbremszylinder-Halte- Staffa pompa del freno 1 Demi-palier de maître-cylin- dre de frein 1 rung 1 Pompa del freno 2 Maître-cylindre de frein 2...
Page 552 All manuals and user guides at all-guides.com CHAS HANDLEBAR EC5B5000 ASSEMBLY AND INSTALLATION Handlebar 1. Install: Handlebar 1 Handlebar upper holder 2 Bolt (handlebar upper holder) 3 28 Nm (2.8 m · kg, 20 ft · lb) NOTE: The handlebar upper holder should be installed with the punched mark a forward.
Page 553 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANUBRIO ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAGGIO INSTALLA- Lenker Guidon ZIONE 1. Montieren: Monter: Manubrio Guidon 1 Lenker 1 Installare: Oberer Lenkerhalter 2 Manubrio 1 Demi-palier supérieur de gui- don 2 Schraube (Oberer Lenker- Supporto manubrio superiore...
Page 554 All manuals and user guides at all-guides.com CHAS HANDLEBAR 4. Install: Collar 1 Throttle cables 2 To tube guide 3. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable wind- ing portion. 5. Install: Throttle cable cap 1 Screw (throttle cable cap) 2 4 Nm (0.4 m ·...
Page 555 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANUBRIO 4. Montieren: Monter: Installare: Collerette 1 Hülse 1 Collarino 1 Câbles d’accélération 2 Gaszüge 2 Cavi acceleratore 2 Sur le guide de tube 3. (am Führungsrohr 3) Alla guida del tubo 3. HINWEIS: N.B.: NOTA:...
Page 556 All manuals and user guides at all-guides.com CHAS HANDLEBAR 7. Install: Light switch 1 2 Nm (0.2 m · kg, 1.4 ft · lb) 8. Install: Engine stop switch 1 Clutch lever holder 2 Bolt (clutch lever holder) 3 4 Nm (0.4 m · kg, 2.9 ft · lb) Decompression lever holder 4 Bolt (decompression lever holder) 5 4 Nm (0.4 m ·...
Page 557 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANUBRIO 7. Einbauen: Posér: Installare: Contacteur d’éclairage 1 Lichtschalter 1 Interruttore luci 1 2 Nm (0,2 m · kg) 2 Nm (0,2 m · kg, 1,4 ft · lb) 2 Nm (0,2 m · kg, 1,4 ft · lb) Monter: 8.
Page 558 All manuals and user guides at all-guides.com CHAS HANDLEBAR 11. Fasten the decompression cable 1 and clutch cable 2 with a clamp 3. 12. Insert the end of the fuel breather hose 1 into the hole of the steering stem. 5 - 46...
Page 559 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANUBRIO 11. Den Dekompressionsseilzug 11. Attacher le câble de décompres- 11. Fissare il cavo di decompressione sion 1 et le câble d’embrayage 1 und den Kupplungsseilzug 1 ed il cavo della frizione 2 con 2 à...
Page 560 All manuals and user guides at all-guides.com CHAS STEERING EC560000 STEERING Extent of removal: 1 Lower bracket removal 2 Bearing removal Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Page 561 All manuals and user guides at all-guides.com DIRECTION LKKOPF CHAS STERZO DIRECTION Organisation de la dépose: 1 Dépose du té inférieur 2 Dépose du roulement Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA DIRECTION AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque...
Page 562 All manuals and user guides at all-guides.com CHAS STEERING Extent of removal Order Part name Q’ty Remarks Upper bearing Lower bearing Refer to “REMOVAL POINTS”. Ball race Refer to “REMOVAL POINTS”. 5 - 48...
Page 563 All manuals and user guides at all-guides.com DIRECTION LKKOPF CHAS STERZO Organisation de la dépose Ordre Nom de pièce Qté Remarques Roulement supérieur Roulement inférieur Se reporter à “POINTS DE DEPOSE”. Cage à billes Se reporter à “POINTS DE DEPOSE”. ETAPES DE SERRAGE: Serrer l’écrou crénelé...
Page 564 All manuals and user guides at all-guides.com CHAS STEERING EC563000 REMOVAL POINTS Steering ring nut 1. Remove: Steering ring nut 1 Use the steering nut wrench 2. Steering nut wrench: YU-33975/90890-01403 WARNING Support the steering stem so that it may not fall down.
Page 565 All manuals and user guides at all-guides.com DIRECTION LKKOPF CHAS STERZO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Lenkerringmutter Ecrou crénelé de direction Ghiera 1. Demontieren: Déposer: Rimuovere: Ecrou crénelé de direction 1 Lenkerringmutter 1 Ghiera 1 Den Hakenschlüssel 2 ver- Utiliser la clé...
Page 566 All manuals and user guides at all-guides.com CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: Bearing 1 Ball race Pitting/damage → Replace bearings and ball races as a set. Install the bearing in the ball races.
Page 567 All manuals and user guides at all-guides.com DIRECTION LKKOPF CHAS STERZO Lager und Laufring Roulement et cage à billes Cuscinetto e pista 1. Die Lager und Laufringe in Lö- Nettoyer les roulements et les Lavare i cuscinetti e le piste con sungsmittel waschen.
Page 568 All manuals and user guides at all-guides.com CHAS STEERING 4. Install: Washer 1 Steering ring nut 2 7 Nm (0.7 m · kg, 5.1 ft · lb) Tighten the steering ring nut using the steering nut wrench 3. Refer to “STEERING HEAD INSPEC- TION AND ADJUSTMENT”...
Page 569 All manuals and user guides at all-guides.com DIRECTION LKKOPF CHAS STERZO 4. Montieren: Monter: Installare: Rondelle 1 Unterlegscheibe 1 Rondella 1 Ecrou crénelé de direction 2 Lenkerringmutter 2 Ghiera 2 7 Nm (0,7 m · kg) 7 Nm (0,7 m · kg, 5,1 ft · lb) 7 Nm (0,7 m ·...
Page 570 All manuals and user guides at all-guides.com CHAS STEERING 9. After tightening the nut, check the steer- ing for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little. 10. Adjust: Front fork top end a Front fork top end (standard) a: 7 mm (0.28 in) * 8mm (0.31 in)
Page 571 All manuals and user guides at all-guides.com DIRECTION LKKOPF CHAS STERZO 9. Nach dem Festziehen der Après avoir serré l’écrou, vérifier Dopo aver serrato la ghiera, con- Mutter Lenkkopf si le mouvement de la direction trollare il movimento agevole Leichtgängigkeit prüfen. Bei est régulier.
Page 572 All manuals and user guides at all-guides.com CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Page 573 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE BRAS OSCILLANT Organisation de la dépose: 1 Dépose du bras oscillant Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU BRAS OSCILLANT AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque approprié...
Page 574 All manuals and user guides at all-guides.com CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY Extent of removal: 1 Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q’ty Remarks SWINGARM DISASSEMBLY Relay arm Connecting rod Collar...
Page 575 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE DEMONTAGE DU BRAS OSCILLANT 1 Démontage du bras oscillant 2 Dépose et démontage de la bielle Organisation de la dépose: 3 Dépose et démontage du bras de relais Organisation de la dépose Ordre Nom de pièce...
Page 576 All manuals and user guides at all-guides.com CHAS SWINGARM EC573000 REMOVAL POINTS EC573200 Bearing 1. Remove: Bearing 1 NOTE: Install the bearing by pressing its outer race. INSPECTION Wash the bearings, bushings, collars, and cov- ers in a solvent. Swingarm 1.
Page 577 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Lager Roulement Cuscinetto 1. Demontieren: Déposer: Rimuovere: Roulement 1 Lager 1 Cuscinetto 1 HINWEIS: N.B.: NOTA: Das Lager am äußeren Laufring ein- Monter le roulement en appuyant sur la Installare cuscinetto...
Page 578 All manuals and user guides at all-guides.com CHAS SWINGARM EC575000 ASSEMBLY AND INSTALLATION EC575201 Bearing and oil seal 1. Install: Bearing 1 Oil seal 2 To swingarm. NOTE: Apply the molybdenum disulfide grease on the bearing when installing. Install the bearing by pressing it on the side having the manufacture’s marks or numbers.
Page 579 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAGGIO INSTALLA- Lager und Dichtringe Roulement et bague d’étanchéité ZIONE 1. Montieren: Monter: Cuscinetto e paraolio Roulement 1 Lager 1 Installare: Bague d’étanchéité...
Page 580 All manuals and user guides at all-guides.com CHAS SWINGARM Swingarm 1. Install: Bushing 1 Thrust bearing 2 Oil seal 3 Collar 4 To swingarm 5. NOTE: Apply the molybdenum disulfide grease on the bushings, thrust bearings and oil seal lips. 2.
Page 581 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Schwinge Bras oscillant Forcellone oscillante 1. Montieren: Monter: Installare: Bague 1 Buchse 1 Boccola 1 Roulement de butée 2 Drucklager 2 Cuscinetto di spinta 2 Bague d’étanchéité 3 Dichtring 3 Paraolio 3 Collerette 4...
Page 582 All manuals and user guides at all-guides.com CHAS SWINGARM 5. Install: Relay arm 1 Bolt (relay arm) 2 Washer 3 Nut (relay arm) 4 To swingarm. NOTE: Apply the molybdenum disulfide grease on the bolt. Do not tighten the nut yet. 6.
Page 583 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE 5. Montieren: Monter: Installare: Bras de relais 1 Umlenkhebel 1 Leva di rinvio 1 Boulon (bras relais) 2 Schraube (Umlenkhebel) 2 Bullone (leva di rinvio) 2 Rondelle 3 Unterlegscheibe 3 Rondella 3 Ecrou (bras relais) 4...
Page 584 All manuals and user guides at all-guides.com 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.
Page 585 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE 10. Festziehen: 10. Serrer: 10. Serrare: Ecrou (bielle) 1 Mutter (Übertragungshebel) Dado (biella) 1 80 Nm (8,0 m · kg, 58 ft · lb) 80 Nm (8,0 m · kg, 58 ft · lb) 80 Nm (8,0 m ·...
Page 586 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER Extent of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal Order Part name Q’ty Remarks REAR SHOCK ABSORBER WARNING REMOVAL Support the machine securely so there is no Preparation for removal...
Page 587 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE AMORTISSEUR ARRIERE Organisation de la dépose: 1 Dépose de l’amortisseur arrière 2 Démontage de l’amortisseur arrière Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE L’AMORTISSEUR AVERTISSEMENT Préparation pour la dépose ARRIERE...
Page 588 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q’ty Remarks Locknut Only loosening. Adjuster Only loosening. Lower spring guide Upper spring guide Spring (rear shock absorber) Bearing Refer to “REMOVAL POINTS”. 5 - 61...
Page 589 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Organisation de la dépose Ordre Nom de pièce Qté Remarques Contre-écrou Desserrer uniquement. Dispositif de réglage Desserrer uniquement. Guide de ressort (inférieur) Guide de ressort (supérieur) Ressort (amortisseur arrière) Roulement Se reporter à...
Page 590 1. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. WARNING To dispose of a damaged or worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5 - 62...
Page 591 WARNUNG Confier la mise au rebut d’un amortis- rato, rivolgersi ad un rivenditore Den Stoßdämpfer vom Yamaha- seur endommagé ou usé à un conces- Yamaha per questa procedura di Händler entsorgen lassen. sionnaire Yamaha smaltimento. 5 - 62...
Page 592 All manuals and user guides at all-guides.com 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.
Page 593 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Lager Roulement Cuscinetto 1. Demontieren: Déposer: Rimuovere: Sicherungsring (Oberes La- Bague d’arrêt (roulement supé- Anello di arresto (cuscinetto rieur) 1 ger) 1 superiore) 1 HINWEIS:...
Page 594 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585300 Bearing 1. Install: Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. CAUTION: Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear- ing is press fitted.
Page 595 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAGGIO INSTALLA- Lager Roulement ZIONE 1. Montieren: Monter: Cuscinetto Roulement supérieur 1 Oberes Lager 1 Installare: Cuscinetto superiore 1 HINWEIS: N.B.: Das Lager am äußeren Laufring Monter le roulement parallèlement NOTA:...
Page 596 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER 2. Tighten: Adjuster 1 3. Adjust: Spring length (installed) a Spring length (installed) a: Standard Extent of length adjustment 240.5 mm (9.47 in) 240.5 ~ 258.5 mm * 247 mm (9.72 in) (9.47 ~ 10.18 in) **243.5 mm (9.59 in) * For EUROPE...
Page 597 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE 2. Festziehen: Serrer: Serrare: Dispositif de réglage 1 Einstellmutter 1 Registro 1 Régler: 3. Einstellen: Regolare: Longueur de ressort (monté) a Feder-Einbaulänge a Lunghezza molla (installata) Longueur de ressort Feder-Einbaulänge a (monté) a: Lunghezza molla (instal-...
Page 598 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER 2. Install: Bushing 1 Collar 2 Dust seal 3 NOTE: Apply the molybdenum disulfide grease on the bearing. Apply the lithium soap base grease on the bushing, collars and dust seals. Install the dust seals with their lips facing outward.
Page 599 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE 2. Montieren: Monter: Installare: Douille 1 Buchse 1 Boccola 1 Collerette 2 Hülse 2 Collarino 2 Joint antipoussière 3 Staubschutzring 3 Guarnizione parapolvere 3 HINWEIS: N.B.: NOTA: Molybdändisulfidfett auf das Lager Enduire le roulement de graisse au Applicare grasso al disolfuro di molib-...
Page 600 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER 8. Install: Band 1 Taillight connector 2 5 - 67...
Page 601 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE 8. Montieren: Monter: Installare: Bande 1 Band 1 Band 1 Rücklicht-Steckverbinder 2 Connecteur de la lampe arrière Connettore del fanalino poste- riore 2 5 - 67...
Page 602 All manuals and user guides at all-guides.com – ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 Headlight COLOR CODE Sb ....Sky blue 2 Voltage regulator B...... Black W .....White Br ....Brown 3 Engine stop switch Y ......Yellow G .....
Page 603 All manuals and user guides at all-guides.com COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE – ELEKTRISCHE BAUTEILE UND SCHALTPLAN ELEC COMPONENTI ELETTRICI E SCHEMA DI CABLAGGIO ELEKTRISCHE PARTIE IMPIANTO ANLAGE ELECTRIQUE ELETTRICO COMPOSANTS ELECTRI- ELEKTRISCHE BAUTEI- COMPONENTI ELET- LE UND SCHALTPLAN QUES ET SCHEMA DE TRICI E SCHEMA DI ELEKTRISCHE BAUTEILE...
Page 604 MAP-CONTROLLED CDI UNIT MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the WR250F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved according to various riding conditions.
Page 605 BLOC CDI CONTROLE PAR MICROPROCESSEUR BLOC CDI CONTROLE PAR MICROPROCESSEUR La WR250F est dotée d’un système d’allumage CDI contrôlé par microprocesseur. Le microprocesseur du bloc CDI détecte en permanence le régime du moteur ainsi que la position du papillon des gaz, puis détermine l’avance à l’allumage optimale pour chaque condition d’utilisation. Cette caractéristi- que garantit une réaction rapide du papillon adaptée à...
Page 606 ELEC KENNFELDGESTEUERTES CDI-ZÜNDSYSTEM KENNFELDGESTEUERTES CDI-ZÜNDSYSTEM Die WR250F ist mit einer kennfeldgesteuerten CDI-Zündanlage ausgestattet. Der Mikroprozessor in der CDI-Zündbox ist ständig über die Motordrehzahl und Drosselklappenpo- sition informiert und kann dadurch den optimalen Zündzeitpunkt im gesamten Lastbereich bestim- men. Dies sorgt stets für das bestmögliche Ansprechverhalten des Motors.
Page 607 UNITÀ CDI CONTROLLATA DA MAPPA UNITÀ CDI CONTROLLATA DA MAPPA Il modello WR250F impiega un sistema di accensione CDI controllata da mappa. Il microcomputer nell’unità CDI rileva la velocità del motore e la posizione della valvola a farfalla, determi- nando così la fasatura di accensione ottimale attraverso l’intera gamma operativa. In questo modo, è possibile ottenere una risposta rapida della valvola a farfalla a diverse condizioni di guida.
Page 608 All manuals and user guides at all-guides.com – ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark *Clean or replace Spark gap test...
Page 609 All manuals and user guides at all-guides.com – ELEC SYSTEME D’ALLUMAGE SYSTEME D’ALLUMAGE ETAPES DU CONTROLE Se référer au tableau suivant lors de l’inspection du système d’allumage lors de pannes. Suivre le procédé suivant pour déterminer si le mauvais fonctionnement du moteur est dû à une panne dans le circuit d’allumage et pour vérifier une bougie qui ne produit pas d’étincelle.
Page 610 All manuals and user guides at all-guides.com – ELEC ZÜNDANLAGE ZÜNDANLAGE FEHLERSUCHE Bei der Überprüfung der Zündanlage auf mögliche Störungen ist das folgende Ablaufdiagramm zu beachten. Folgendes Diagramm hilft zündanlagen- und zündkerzenbedingte Motorstörungen zu beheben. Zündfunke Zündfunkenstrecke *Zündkerze reinigen kontrollieren oder erneuern.
Page 611 All manuals and user guides at all-guides.com – ELEC IMPIANTO DI ACCENSIONE IMPIANTO DI ACCENSIONE FASI DI ISPEZIONE Utilizzare la procedura seguente per controllare la possibilità che un cattivo funzionamento del motore sia attribuibile ad un guasto al sistema di accensione o per controllare la candela che non emette scintille. Scintilla Test della distanza tra gli *Pulire o sostituire la...
Page 612 All manuals and user guides at all-guides.com – ELEC IGNITION SYSTEM SPARK GAP TEST Å 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (ignition checker 2) as shown. Spark plug cap 3 Spark plug 4 Å...
Page 613 All manuals and user guides at all-guides.com SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE ZÜNDFUNKENSTRECKE KON- TEST DE LA LONGUEUR D’ETIN- Test della distanza tra gli elettrodi TROLLIEREN CELLE D’ALLUMAGE Staccare il cappuccio della can- 1. Den Zündkerzenstecker von Déconnecter le capuchon de bou- dela.
Page 614 All manuals and user guides at all-guides.com – 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...
Page 615 All manuals and user guides at all-guides.com SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE ZÜNDSPULE KONTROLLIEREN CONTROLE BOBINE ISPEZIONE BOBINA DI ACCEN- 1. Kontrollieren: D’ALLUMAGE SIONE Primärspulen-Widerstand Vérifier: Ispezionare: Unvorschriftsmäßig → Résistance de bobine primaire Resistenza avvolgimento pri- Hors spécification → Rempla- Erneuern.
Page 616 All manuals and user guides at all-guides.com – ELEC IGNITION SYSTEM 2. Inspect: Charging coil 1 resistance Out of specification → Replace. Tester (+) lead → Brown lead 1 Tester (–) lead → Green lead 2 Charging coil 1 Tester selector resistance position 640 ~ 960 Ω...
Page 617 All manuals and user guides at all-guides.com SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE 2. Kontrollieren: Vérifier: Ispezionare: Widerstand der Erregerspu- Résistance de bobine de charge Resistenza bobina di carica 1 Fuori specifica → Sostituire. le 1 Hors spécification → Rempla- Unvorschriftsmäßig →...
Page 618 All manuals and user guides at all-guides.com – ELEC THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. No good Check entire ignition Repair or replace. system for connection.
Page 619 All manuals and user guides at all-guides.com – ELEC CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ ETAPES DU CONTROLE Si le capteur de papillon des gaz ne fonctionne pas, effectuer les contrôles suivants. Vérifier la connexion de tout le Mauvais Réparer ou remplacer.
Page 620 All manuals and user guides at all-guides.com – ELEC DROSSELKLAPPEN-POSITIONSSENSOR DROSSELKLAPPEN-POSITIONSSENSOR INSPEKTIONSSCHRITTE Wenn Drosselklappen-Positionssensor nicht arbeitet, mit den folgenden Schritten überprüfen. Nicht in Ordnung Die gesamte Zündanlage Erneuern oder instand auf Anschluß überprüfen. setzen. In Ordnung Drosselklap- Nicht in Ordnung Den Drosselklappen-Positi- pen-Positions- Erneuern.
Page 621 All manuals and user guides at all-guides.com SISTEMA SENSORE DELLA POSIZIONE DELLA – ELEC VALVOLA A FARFALLA SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA FASI DI ISPEZIONE Se il sensore di posizione della valvola a farfalla non funziona, seguire la seguente procedura. Controllare il collegamento Non funziona dell’intero...
Page 622 All manuals and user guides at all-guides.com – ELEC THROTTLE POSITION SENSOR SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. THROTTLE POSITION SENSOR COIL INSPECTION 1. Inspect: Throttle position sensor coil resistance Out of specification →...
Page 623 All manuals and user guides at all-guides.com CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ – DROSSELKLAPPEN-POSITIONSSENSOR ELEC SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA INSPEKTION DER STECKVERBIN- CONTROLE DES CONNEXIONS ISPEZIONE DEI COLLEGAMENTI DUNGEN UND KABELANSCHLÜS- DES COUPLEURS ET DES FILS DEGLI ACCOPPIATORI E DEI Vérifier: CAVI...
Page 624 All manuals and user guides at all-guides.com – ELEC THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR REPLACEMENT AND ADJUSTMENT 1. Remove: Throttle position sensor coupler Screw (throttle position sensor) 1 Washer 2 Throttle position sensor 3 NOTE: Loosen the screws (throttle position sensor) using the T20 bit (tamper resistant fastener type).
Page 625 All manuals and user guides at all-guides.com CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ – DROSSELKLAPPEN-POSITIONSSENSOR ELEC SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA TPS-AUSTAUSCH UND EINSTEL- REMPLACEMENT ET REGLAGE SOSTITUZIONE REGOLA- LUNG DU CAPTEUR DE PAPILLON DES ZIONE DEL SENSORE DI POSI- 1.
Page 626 All manuals and user guides at all-guides.com – ELEC THROTTLE POSITION SENSOR SYSTEM 6. Adjust: Throttle position sensor coil resistance at idle speed Adjustment steps: Adjust the angle of the throttle position sen- sor 1 to obtain the resistance calculated (example: 650 ~ 750 Ω) Tester (+) lead →...
Page 627 All manuals and user guides at all-guides.com CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ – DROSSELKLAPPEN-POSITIONSSENSOR ELEC SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA 6. Einstellen: Régler: Regolare: TPS-Spulenwiderstand bei Résistance de la bobine de cap- Resistenza bobina sensore di Leerlauf teur de papillon des gaz à...
Page 628 All manuals and user guides at all-guides.com – ELEC LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible problems. No good Check the bulb and bulb Replace the bulb and/ socket.
Page 629 All manuals and user guides at all-guides.com – ELEC SYSTEME D’ECLAIRAGE SYSTEME D’ECLAIRAGE PROCEDURES DE VERIFICATION Se référer au tableau suivant lors de l’inspection du système d’allumage lors de pannes. Mauvais Contrôler l’ampoule et le culot Changer l’ampoule et/ou le d’ampoule.
Page 630 All manuals and user guides at all-guides.com – ELEC LICHTANLAGE LICHTANLAGE KONTROLLSCHRITTE Bei der Überprüfung der Zündanlage auf mögliche Störungen ist das folgende Ablaufdiagramm zu beachten. Nicht in Ordnung Lampe und Lampenstecker Lampe und/oder Lam- überprüfen. penstecker erneuern. In Ordnung Die gesamte Lichtanlage auf Nicht in Ordnung einwandfreie Verbindungen...
Page 631 All manuals and user guides at all-guides.com – ELEC IMPIANTO DI ILLUMINAZIONE IMPIANTO DI ILLUMINAZIONE FASI DI ISPEZIONE Vedere lo schema a blocchi che segue quando si controlla l’impianto di accensione per verificare l’esistenza di possibili problemi. Non funziona Controllare la lampada ed il por- Sostituire la lampada e/o il talampada.
Page 632 All manuals and user guides at all-guides.com – ELEC LIGHTING SYSTEM LIGHT SWITCH INSPECTION 1. Inspect: Light switch continuity Tester (+) lead → Yellow lead 1 Tester (–) lead → Blue lead 2 Tester selec- tor position Ω × 1 →...
Page 633 All manuals and user guides at all-guides.com SYSTEME D’ECLAIRAGE LICHTANLAGE – ELEC IMPIANTO DI ILLUMINAZIONE LICHTSCHALTER KONTROLLIE- VERIFICATION INTERRUPTEUR ISPEZIONE DELL’INTERRUT- LUMIERES TORE LUCI 1. Kontrollieren: Vérifier: Ispezionare: Lichtschalterfunktion conducteur interrupteur Conduttività dell’interruttore lumière luci Pluskabel des Meßgerätes (+) → Gelbes Kabel 1 Fil (+) de multimètre →...
Page 634 All manuals and user guides at all-guides.com T U N SETTING EC700000 TUNING EC710000 ENGINE Carburetor setting The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is nec- essary to take into consideration the air pres- sure, ambient temperature, humidity, etc., when adjusting the carburetor.
Page 635 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE ABSTIMMUNG MISES AU POINT MESSA A PUNTO MOTOR MOTEUR MOTORE Vergaser einstellen Réglage de carburateur Registrazione del carburatore Das Luft/Kraftstoffgemisch variiert La qualité de l’émulsion air/essence La miscela aria/carburante varia a mit den atmosphärischen Bedin- dépend des conditions atmosphéri- seconda delle condizioni atmosferi-...
Page 636 All manuals and user guides at all-guides.com T U N SETTING CAUTION: The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. Always handle the carburetor and its components carefully.
Page 637 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE ATTENTION: ATTENZIONE: ACHTUNG: Le carburateur est extrêmement Der Vergaser ist extrem emp- Il carburatore è estremamente sen- sensible à toute pénétration de cras- findlich gegen Fremdkörper sibile a materiale estraneo (sporco, ses, sable, eau, etc.
Page 638 All manuals and user guides at all-guides.com T U N SETTING Effects of the setting parts on the throttle valve opening ı Å Å ı Å Closed ı Fully open 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet Main system The FLATCR carburetor has a primary main...
Page 639 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Wirkung der Einstellteile in Bezug Effets des réglages sur l’ouverture du Effetti della registrazione sull’aper- auf die Öffnung der Drosselklappe papillon des gaz tura della valvola a farfalla Å...
Page 640 All manuals and user guides at all-guides.com T U N SETTING 1 Jet needle 2 Main air jet 3 Pilot air jet 4 Needle jet 5 Main jet 6 Pilot jet 7 Pilot screw Main jet adjustment The richness of the air-fuel mixture at full throt- tle can be set by changing the main jet 1.
Page 641 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE 1 Aiguille 1 Düsennadel 1 Spillo del getto 2 Puits d’aiguille 2 Nadeldüse 2 Getto dell’aria del massimo 3 Gicleur principal 3 Hauptdüse 3 Getto dell’aria del minimo 4 Puits d’aiguille 4 Nedeldüse 4 Getto a spillo...
Page 642 All manuals and user guides at all-guides.com T U N SETTING Pilot screw adjustment The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1. Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it.
Page 643 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Einstellung der Leerlaufgemisch- Réglage de la vis de ralenti Regolazione vite di registro del Regulierschraube La richesse de l’émulsion air-essence à minimo Der Kraftstoffgehalt des Luft-Kraft- une ouverture des gaz de 0 à 1/4 se règle È...
Page 644 All manuals and user guides at all-guides.com T U N SETTING Effects of adjusting the pilot jet (reference) Å ı –5% Å Idle ı Fully open Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 to 3/4 open.
Page 645 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Wirkung der Einstellung der Leer- Effets du réglage du gicleur de ralenti Effetti della regolazione del getto del laufdüse (référence) minimo (riferimento) Å ı Å ı Å ı...
Page 646 All manuals and user guides at all-guides.com T U N SETTING Jet needle adjustment The jet needle is adjusted by changing it. OBELP Standard jet needle *OBEGP **OBEHP * For EUROPE ** For CDN, ZA, AUS and NZ The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters.
Page 647 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Düsennadel einstellen Réglage de l’aiguille Regolazione dello spillo del getto Die Düsennadel wird eingestellt, L’aiguille se règle en la changeant. Lo spillo del getto viene regolato sosti- indem sie ausgetauscht wird.
Page 648 All manuals and user guides at all-guides.com T U N SETTING Effects of changing the jet needle (reference) (Diameter of the straight portion) Changing the diameter of the straight portion adjusts the air-fuel mixture when the throttle is 1/8 to 1/4 open. Å...
Page 649 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Wirkung des Austausch Effets du changement d’aiguille (réfé- Effetti della modifica dello spillo del s der Düsennadel rence) getto (riferimento) (Durchmesser des geraden Teils) (Diamètre de la partie recriligne) (Diametro della parte dritta) Der Durchmesser des geraden Teils Une modification du diamètre de la par-...
Page 650 All manuals and user guides at all-guides.com T U N SETTING EC71Q000 Carburetor setting parts Part name Size Part number Main jet Rich #185 4MX-14943-44 #182 4MX-14943-94 #180 4MX-14943-43 #178 4MX-14943-93 #175 4MX-14943-42 #172 4MX-14943-92 (STD) #170 4MX-14943-41 #168 4MX-14943-91 #165 4MX-14943-40 #162...
Page 651 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Vergaser-Einstellteile Pièces modifiables du carburateur Parti di registrazione del carburatore Numéro de Grö- Teilenum- Denomina- Numero di Nom de pièce Taille Bauteil pièce ße zione sura pezzo Gicleur principal N˚185 4MX-14943-44...
Page 652 All manuals and user guides at all-guides.com T U N SETTING Examples of carburetor setting depending on symptom Symptom Setting Checking Discoloration of spark plug → At full throttle Increase main jet calibration no. Hard breathing (Gradually) If tan color, it is in good condition. Shearing noise If cannot be corrected: Whitish spark plug...
Page 653 All manuals and user guides at all-guides.com T U N REGLAGE Exemples de réglages de carburateur en fonction des symptômes Symptômes Réglages Contrôles Décoloration de bougie → Monter un gicleur principal de n˚ de cali- A pleine ouverture des gaz bre supérieur Brun clair = bon état Crachotements...
Page 654 All manuals and user guides at all-guides.com T U N EINSTELLUNG Beispiele für die Vergasereinstellung in bezug auf bestimmte Symptome Symptom Einstellung Prüfung Bei Vollgas Hauptdüsen-Nr. erhöhen (schrittweise) Verfärbung der Zündkerze: “Schweres Atmen” Rehbraune Färbung weist auf guten Abschergeräusch Zustand hin. Weißliche Zündkerze Falls nicht korrigiert werden kann: Schwimmerventilsitz verstopft...
Page 655 All manuals and user guides at all-guides.com T U N REGISTRAZIONE Esempi di registrazione del carburatore a seconda dei sintomi Sintomo Registrazione Controllo Scolorimento della candela → Con la valvola a farfalla Aumentare il n. di taratura del getto del completamente aperta massimo.
Page 656 All manuals and user guides at all-guides.com T U N SETTING EC720000 CHASSIS Selection of the secondary reduction ratio (Sprocket) Secondary Number of rear wheel sprocket teeth reduction = Number of drive sprocket teeth ratio Standard secondary 52/13 (4.000) reduction ratio <Requirement for selection of secondary gear reduction ratio>...
Page 657 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE FAHRGESTELL PARTIE CYCLE PARTE CICLISTICA Sekundärüntersetzungsverhältnis Sélection du taux de réduction secon- Selezione rapporto di riduzione secon- (Kettenräder) wählen daire (pignons) daria (corona dentata) Anzahl der Zähne Nombre de dents Numero di denti della de la couronne...
Page 658 All manuals and user guides at all-guides.com T U N SETTING EC72N000 Drive and driven sprockets setting parts Part name Size Part number Drive sprocket 1 (STD) 9383B-13218 Rear wheel 5GS-25448-50 sprocket 2 5GS-25450-50 (STD) 5GS-25452-50 5PH-25454-50 EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit.
Page 659 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Antriebsritzel und Kettenräder Pièces de réglage des pignons menant Parti di regolazione delle corone den- et de la couronne arrière tate conduttrici e condotte Teilenum- Bauteil Größe Numéro Denomina- Misu...
Page 660 All manuals and user guides at all-guides.com T U N SETTING EC722011 Front fork setting The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1.
Page 661 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Teleskopgabel einstellen Réglages de la fourche avant Registrazione forcella anteriore Die Einstellung der Gabel sollte ent- La registrazione della forcella anteriore Régler la fourche avant en fonction de la va effettuata a seconda delle sensazioni sprechend dem Gefühl des Fahrers, sensation lors de la conduite ainsi que...
Page 662 All manuals and user guides at all-guides.com T U N SETTING EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. CAUTION: Do not install three or more adjustment washers for each front fork.
Page 663 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Federvorspannung einstellen Réglage de tension initiale du ressort Regolazione precarico Die Federvorspannung wird durch Le tension initiale du ressort a été ajustée Il precarico della molla viene regolato en montant la rondelle de réglage 1 den Einbau einer Einstellscheibe 1 installando la rondella di regolazione 1...
Page 664 All manuals and user guides at all-guides.com T U N SETTING 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar.
Page 665 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE 2. Harte Feder Ressort dur Impiego di una molla rigida Eine harte Feder bewirkt prin- En principe, un ressort dur offre Generalmente una molla rigida dà zipiell ein hartes Fahrgefühl. une sensation de conduite dure.
Page 666 All manuals and user guides at all-guides.com T U N SETTING EC72P000 Front fork setting parts Adjustment washer 1 TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 4SS-23364-L0 Front fork spring 2 [Equal pitch spring] I.D. SPRING SPRING TYPE MARK RATE...
Page 667 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Vorderradgabel-Einstellteile Pièces de réglage de la fourche avant Parti di regolazione della forcella Rondelle de réglage 1 Einstellscheibe 1 anteriore Rondella di regolazione 1 TYPE TEILENUM- Numéro de pièce TYP (Dicke) (épaisseur) NUMERO DI...
Page 668 All manuals and user guides at all-guides.com T U N SETTING EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the fol- lowing two factors: 1.
Page 669 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Hinterradaufhängung einstellen Réglage de la suspension arrière Registrazione della sospensione poste- Die Einstellung der Hinterradaufhän- Effectuer le réglage de la suspension riore gung soll entsprechend dem Gefühl arrière en fonction de la sensation lors de La registrazione della sospensione poste- des Fahrers, nach einer Testfahrt...
Page 670 All manuals and user guides at all-guides.com T U N SETTING NOTE: If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re- evaluation.
Page 671 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE HINWEIS: N.B.: NOTA: Le ressort peut s’allonger au fur et à Die Federeinbaulänge kann sich Se il veicolo è nuovo dopo il rodaggio mesure de la période de rodage. Il est beim Einfahren verändern, u.a.
Page 672 All manuals and user guides at all-guides.com T U N SETTING CAUTION: When using a rear shock absorber other than currently installed, use the one whose overall length a does not exceed the stan- dard as it may result in faulty performance. Never use one whose overall length is greater than standard.
Page 673 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE ATTENTION: ATTENZIONE: ACHTUNG: Lors du remplacement de l’amortis- Beim Austausch des Federbeins Quando si impiega un ammortizzatore seur arrière, veiller à monter un darauf achten, daß die Gesamtlän- posteriore diverso da quello installato, amortisseur dont la longueur totale a ge a das Standardmaß...
Page 674 All manuals and user guides at all-guides.com T U N SETTING EC72Q000 Rear shock absorber setting parts Rear shock spring 1 [Equal pitch spring] I.D. SPRING SPRING SPRING TYPE COLOR/ FREE RATE PART NUMBER POINT LENGTH 5DH-22212-70 Brown/1 SOFT 5DH-22212-10 Green/1 5DH-22212-20 Red/1...
Page 675 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N REGISTRAZIONE Hinterradstoßdämpfer-Einstell- Pièces de réglage de l’amortisseur Parti di regolazione dell’ammortizza- teile arrière tore posteriore Ressort d’amortisseur arrière 1 Hinterradstoßämpfer-Schrauben- Molla dell’ammortizzatore posteriore feder 1 [Ressort à pas égal] [Feder mit gleichmäßiger Gewinde- [Molla con passo costante] Cons-...
Page 676 All manuals and user guides at all-guides.com T U N SETTING EC72H002 Suspension setting Front fork NOTE: If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.9 in).
Page 677 All manuals and user guides at all-guides.com T U N SETTING Rear shock absorber NOTE: If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. Adjust the rebound damping in 2-click increments or decrements.
Page 678 All manuals and user guides at all-guides.com T U N REGLAGE Réglage de la suspension Fourche avant N.B.: Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectuer un nouveau réglage en se référant aux procédés repris dans ce tableau. Avant d’effectuer toute modification, régler la longueur enfoncée de l’amortisseur arrière comprimé...
Page 679 All manuals and user guides at all-guides.com T U N REGLAGE Amortisseur arrière N.B.: Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectuer un nouveau réglage en se référant aux procédés repris dans ce tableau. Régler la force de rebondissement de 2 clics dans un sens ou l’autre.
Page 680 All manuals and user guides at all-guides.com T U N EINSTELLUNG Fahrwerksabstimmung Teleskopgabel HINWEIS: Liegen bei Normaleinstellung folgende Symptome vor, wie folgt vorgehen. Vor der Einstellung der Gabel das Federbein auf die Standard-Federeinbaulänge von 90–100 mm einstellen. Strecke Große Mittlere Kleine Symptom Prüfen...
Page 681 All manuals and user guides at all-guides.com T U N EINSTELLUNG Federbein HINWEIS: Liegen bei Normaleinstellung folgende Symptome vor, wie folgt vorgehen. Die Zugstufendämpfung jeweils um 2 Rasterstufen stärker oder schwächer verstellen. Die Tiefdruckdämpfung jeweils um 1 Rasterstufe stärker oder schwächer verstellen. Die Hochdruckdämpfung jeweils um eine 1/6-Drehung stärker oder schwächer verstellen.
Page 682 All manuals and user guides at all-guides.com T U N REGISTRAZIONE Registrazione sospensioni Forcella anteriore NOTA: Se si verifica uno dei seguenti sintomi con la posizione standard, effettuare la ri-registrazione facendo riferimento alla procedura di registrazione indicata nella stessa tabella. Prima di ogni eventuale modifica, impostare la lunghezza abbassata dell’ammortizzatore posteriore sul valore normale di 90 ~ 100 mm (3,5 ~ 3,9 in).
Page 683 All manuals and user guides at all-guides.com T U N REGISTRAZIONE Ammortizzatore posteriore NOTA: Se si verifica uno dei seguenti sintomi con la posizione normale, effettuare la ri-registrazione facendo riferimento alla procedura di regolazione indicata nella stessa tabella. Regolare lo smorzamento di espansione in incrementi o decrementi di 2 scatti. Regolare lo smorzamento di compressione bassa in incrementi o decrementi di 1 scatto.
Page 684 All manuals and user guides at all-guides.com...
Page 685 All manuals and user guides at all-guides.com...
Page 686 All manuals and user guides at all-guides.com YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN 2000 · 11 - 2.5 × 1 CR PRINTED ON RECYCLED PAPER 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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