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• Page 1
  OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGS-HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250F(T) 5XC-28199-31…
• Page 2
  EC010010 YZ250F(T) OWNER’S SERVICE MANUAL ©2004 by Yamaha Motor Co., Ltd. 1st Edition, July 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan…
• Page 3
  EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha YZ 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 4: Important Notice

  IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regula- tions before riding.

• Page 5
  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 6
  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 7
  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 8
  EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., •…
• Page 9
  ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC INFO Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. INSP 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical CHAS ELEC…
• Page 10
  EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING…

• Page 11: Table Of Contents

  EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION ………..1-1 MACHINE IDENTIFICATION …..1-2 IMPORTANT INFORMATION ….1-3 CHECKING OF CONNECTION ….1-6 SPECIAL TOOLS ……..1-7 CONTROL FUNCTIONS ……1-10 FUEL …………1-13 STARTING AND BREAK-IN ….1-14 TORQUE-CHECK POINTS ……1-18 CLEANING AND STORAGE ….1-19 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ….2-1 MAINTENANCE SPECIFICATIONS ..2-4 GENERAL TORQUE…

• Page 12
  CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ……..4-1 EXHAUST PIPE AND SILENCER …..4-3 RADIATOR ……….4-5 CARBURETOR ……….4-8 CAMSHAFTS ………..4-21 CYLINDER HEAD ……..4-30 VALVES AND VALVE SPRINGS ….4-33 CYLINDER AND PISTON ……4-42 CLUTCH ………..4-49 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER ..4-56 BALANCER ……….4-63 OIL PUMP ……….4-66…
• Page 13
  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 CHAPTER 7 TUNING ENGINE …………7-1 CHASSIS ……….7-11…

• Page 14: General Information

  DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever NOTE: 2 Hot starter lever • The machine you have purchased may differ 3 Front brake lever slightly from those shown in the following. 4 Throttle grip • Designs and specifications are subject to 5 Radiator cap 6 Fuel tank cap change without notice.

• Page 15: Machine Identification

  There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive 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 16: Important Information

  IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pres- sured water, cover the parts follows. • Silencer exhaust port •…

• Page 17
  IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled.
• Page 18
  IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is posi- tioned opposite to the thrust 3 it receives. See the sectional view.

• Page 19: Checking Of Connection

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

• Page 20: Special Tools

  SPECIAL TOOLS INFO SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.

• Page 21
  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 sur- face, etc. 1 — 9…

• Page 22: Control Functions

  CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar;…

• Page 23
  CONTROL FUNCTIONS INFO EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to acti- vate the front brake. EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine.
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  CONTROL FUNCTIONS INFO EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. WARNING • Never apply additional force to the side- stand. • Remove this sidestand before starting out. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose.

• Page 25: Fuel

  FUEL INFO FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Recommended fuel: Premium unleaded gasoline only with a research octane number of 95 or higher. CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.

• Page 26: Starting And Break-In

  STARTING AND BREAK-IN INFO STARTING AND BREAK-IN WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION: •…

• Page 27
  STARTING AND BREAK-IN INFO 6. Return the cold starter knob to its original position and run the engine at 3,000 ~ 5,000 r/min for 1 or 2 minutes. NOTE: Since this model is equipped with an accelera- tor pump, if the engine is raced (the throttle opened and closed), the air/fuel mixture will be too rich and the engine may stall.
• Page 28
  STARTING AND BREAK-IN INFO STARTING A WARM ENGINE Do not operate the cold starter knob and throt- tle. Pull the hot starter lever 1 and start the engine by kicking the kickstarter crank force- fully with a firm stroke. As soon as the engine starts, Release the hot starter lever to close the air passage.
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  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 30: Torque-Check Points

  TORQUE-CHECK POINTS INFO TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to Steering stem to frame handlebar…

• Page 31: Cleaning And Storage

  CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many com- ponents. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.

• Page 32
  CLEANING AND STORAGE INFO EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the car- buretor float bowl.

• Page 33: Specifications

  SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: YZ250FT (USA, CDN, AUS, NZ) YZ250F (EUROPE, ZA) Model code number: 5XC5 (USA) 5XC6 (EUROPE) 5XC8 (CDN, AUS, NZ, ZA) Dimensions: EUROPE USA, ZA, (Except AUS, NZ for F) Overall length…

• Page 34
  SPEC GENERAL SPECIFICATIONS Oil type or grade: Engine oil (For USA and CDN) At 5 °C (40 °F) or higher È Yamalube 4 (20W-40) or SAE 20W-40 type SG motor oil (Non-Friction modified) At 15 °C (60 °F) or lower É Yamalube 4 (10W-30) or SAE 10W-30 type SG motor oil (Non-Friction modified)
• Page 35
  SPEC GENERAL SPECIFICATIONS Transmission: Primary reduction system Gear Primary reduction ratio 57/17 (3.353) Secondary reduction system Chain drive Secondary reduction ratio 48/13 (3.692) (Except for EUROPE) 49/13 (3.769) (For EUROPE) Transmission type Constant mesh, 5-speed Operation Left foot operation Gear ratio: 1st 30/14 (2.143) 28/16 (1.750) 29/20 (1.450)

• Page 36: Maintenance Specifications

  SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit —- 0.05 mm (0.002 in) Cylinder: Bore size 77.00 ~ 77.01 mm —- (3.0315 ~ 3.0319 in) Out of round limit —- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) —-…

• Page 37
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 92RH2010-114M/114 —- Timing chain adjustment method Automatic —- Valve, valve seat, valve guide: Valve clearance (cold) 0.10 ~ 0.15 mm —- (0.0039 ~ 0.0059 in) 0.17 ~ 0.22 mm —- (0.0067 ~ 0.0087 in) Valve dimensions:…
• Page 38
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit —- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) Valve spring: Free length 37.81 mm (1.49 in)
• Page 39
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston pin bore inside diameter 16.002 ~ 16.013 mm 16.043 mm (0.6300 ~ 0.6304 in) (0.6316 in) Piston pin outside diameter 15.991 ~ 16.000 mm 15.971 mm (0.6296 ~ 0.6299 in) (0.6288 in) Piston rings: Top ring: Type Barrel…
• Page 40
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) —- Quantity —- Warp limit —- 0.1 mm (0.004 in) Clutch spring free length 40.4 mm (1.59 in) 39.4 mm (1.55 in) Quantity —- Clutch housing thrust clearance 0.10 ~ 0.35 mm…
• Page 41
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type —- Oil pump type Trochoid type —- Tip clearance 0.12 mm or less 0.20 mm (0.0047 in or less) (0.008 in) Side clearance 0.09 ~ 0.17 mm 0.24 mm (0.0035 ~ 0.0067 in) (0.009 in)
• Page 42
  SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M10S × 1.0 Spark plug M6 × 1.0 Camshaft cap M12 × 1.0 Cylinder head blind plug screw M6 × 1.0 Cylinder head (stud bolt) M8 × 1.25 (stud bolt) M9 ×…
• Page 43
  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 Crankcase M6 × 1.0 Crankcase bearing stopper M6 × 1.0 Crankcase bearing stopper (crankshaft) M6 ×…
• Page 44
  SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing —- Front suspension: Front fork travel 300 mm (11.8 in) —- Fork spring free length 465 mm (18.3 in) 460 mm (18.1 in) Spring rate, STD K = 4.3 N/mm —- (0.438 kg/mm, 24.5 lb/in)
• Page 45
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Wheel: Front wheel type Spoke wheel —- Rear wheel type Spoke wheel —- 21 × 1.60/Aluminum Front rim size/material —- 19 × 1.85/Aluminum Rear rim size/material —- Rim runout limit: Radial —- 2.0 mm (0.08 in) Lateral —- 2.0 mm (0.08 in)
• Page 46
  SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Upper bracket and outer tube M8 × 1.25 Lower bracket and outer tube M24 × 1.0 Upper bracket and steering stem 14.5 M8 × 1.25 Handlebar holder and upper bracket M28 ×…
• Page 47
  SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb Nipple (spoke) — M8 × 1.25 Rear wheel sprocket M6 × 1.0 Rear brake disc cover M6 × 1.0 Rear brake caliper protector M8 × 1.25 Drive chain puller adjust bolt and locknut Engine mounting: M10 ×…
• Page 48
  248 ~ 372 Ω at 20 °C (68 °F) Pickup coil resistance (color) —- (White – Red) CDI unit-model/manufacturer 5XC-50/YAMAHA (For USA) —- 5XC-60/YAMAHA (Except for USA) —- Ignition coil: Model/manufacturer 5UL-10/DENSO —- Minimum spark gap 6 mm (0.24 in) —- 0.08 ~ 0.10 Ω…

• Page 49: General Torque Specifications

  GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached.

• Page 50: Cable Routing Diagram

  SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank breather hose È Insert the end of the fuel tank Í Fasten the engine stop switch 2 Clutch cable breather hose into the hole in lead, neutral switch lead and 3 Oil tank breather hose the steering stem cap.

• Page 51
  SPEC CABLE ROUTING DIAGRAM Ò Make sure that the throttle Ø Pass the carburetor breather position sensor coupler does hoses and overflow hose so not go out side the chassis. that all there hoses do not con- Ó Fasten the throttle position tact the rear shock absorber.
• Page 52
  SPEC CABLE ROUTING DIAGRAM 1 CDI unit È Pass the hot starter cable and Í First install the CDI unit and 2 Hot starter cable throttle cables through the CDI unit band to the CDI unit 3 Throttle cable (pull) cable guides.
• Page 53
  SPEC CABLE ROUTING DIAGRAM 1 Brake master cylinder È Install the brake hose so that its pipe portion 2 Brake hose holder directs as shown and lightly touches the projection 3 Brake hose on the brake caliper. É Pass the brake hose into the brake hose holders. Ê…
• Page 54
  SPEC CABLE ROUTING DIAGRAM 1 Throttle cable È Fasten the engine stop switch lead to the handlebar. 2 Fuel tank breather hose É Pass the brake hose in front of the number plate. 3 Clamp 4 Clutch cable 5 Hot starter cable 6 Engine stop switch lead 7 Brake hose 8 Hose guide…

• Page 55: Regular Inspection And Adjustments

  If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every…

• Page 56
  INSP MAINTENANCE INTERVALS Every Every After Every As re- third fifth Item Remarks break-in race quired 500 km) 1,000 km) SHIFT FORK, SHIFT CAM, GUIDE BAR Inspect Inspect wear ROTOR NUT Retighten EXHAUST PIPE, SILENCER, PRO- TECTOR Inspect and retighten Clean Replace * Whichever comes first…
• Page 57
  Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE, CONTROL CABLE Yamaha cable lube or SAE 10W-30 motor oil Check routing and connection Inspect dirt and wear on Lubricate the throttle cable on the Inspect and clean (throttle cable) carburetor side.

• Page 58: Engine

  INSP ENGINE/COOLANT LEVEL INSPECTION EC350000 ENGINE 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 59
  INSP COOLANT REPLACEMENT COOLANT REPLACEMENT WARNING Do not remove the radiator cap when the engine is hot. 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.
• Page 60
  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 61
  INSP RADIATOR CAP OPENING PRESSURE INSPECTION/ COOLING SYSTEM INSPECTION RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: • Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Radiator cap tester adapter: YU-33984/90890-01352 NOTE: Apply water on the radiator cap seal. 3 Radiator cap 2.
• Page 62
  INSP CLUTCH ADJUSTMENT NOTE: • Do not apply pressure more than specified pressure. • Radiator should be filled fully. 4. Inspect: • Pressure Impossible to maintain the specified pres- sure for 10 seconds → Repair. • Radiator 1 • Radiator hose joint 2 Coolant leakage →…
• Page 63
  INSP THROTTLE CABLE ADJUSTMENT/ THROTTLE LUBRICATION 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: •…
• Page 64
  INSP HOT STARTER LEVER ADJUSTMENT/ AIR FILTER CLEANING HOT STARTER LEVER ADJUSTMENT 1. Check: • Hot starter lever free play a Out of specification → Adjust. Hot starter lever free play a: 3 ~ 6 mm (0.12 ~ 0.24 in) 2.
• Page 65
  INSP AIR FILTER CLEANING 2. 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 66
  INSP ENGINE OIL LEVEL INSPECTION 7. Install: • Air filter element 1 • Washer • Fitting bolt 2 Nm (0.2 m · kg, 1.4 ft · lb) NOTE: Align the projection a on filter guide with the hole b in air filter case. ENGINE OIL LEVEL INSPECTION 1.
• Page 67
  INSP ENGINE OIL LEVEL INSPECTION (For USA and CDN) Recommended oil: At 5 °C (40 °F) or higher È Yamalube 4 (20W-40) or SAE 20W-40 type SG motor oil (Non- Friction modified) At 15 °C (60 °F) or lower É Yamalube 4 (10W-30) or SAE 10W-30 type SG motor oil (Non- Friction modified)
• Page 68
  INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT 1. Start the engine and warm it up for several 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 69: Engine Oil Replacement

  INSP ENGINE OIL REPLACEMENT 7. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them. Replacement steps: • Remove the oil filter element cover 1 and oil filter element 2. • Check the O-rings 3, if cracked or dam- aged, replace them with a new one.

• Page 70
  INSP OIL PRESSURE INSPECTION/ 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 71
  INSP ENGINE IDLING SPEED ADJUSTMENT/ VALVE CLEARANCE INSPECTION AND ADJUSTMENT ENGINE IDLING SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Adjust: • Engine idling speed Adjustment steps: • Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section.
• Page 72
  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 73
  INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Checking steps: • Turn the crankshaft counterclockwise with a wrench. • 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. on compression stroke.
• Page 74
  INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT • Remove the valve lifters 1 and the pads NOTE: • Place a rag in the timing chain space to prevent pads from falling into the crank- case. • Identity each valve lifter and pad position very carefully so that they can be rein- stalled in their original place.
• Page 75
  INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT • Install the new pads 3 and the valve lift- ers 4. NOTE: • Apply the engine oil on the valve lifters. • Apply the molybdenum disulfide oil on the valve stem ends. • Valve lifter must turn smoothly when rotated with a finger.

• Page 76: Valve Clearance Inspection And Adjustment

  INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT INTAKE MEASURED INSTALLED PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235…

• Page 77: Chassis

  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. •…

• Page 78
  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. Add brake fluid to the level line on the reservoir.

• Page 79: Rear Brake Adjustment

  INSP REAR BRAKE ADJUSTMENT/ FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMENT 1. Check: • Brake pedal height a Out of specification → Adjust. Brake pedal height a: 5 mm (0.20 in) 2. Adjust: • Brake pedal height Pedal height adjustment steps: •…

• Page 80
  INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT • Loosen the pad pin 2. • Remove the brake caliper 3 from the front fork. • Remove the pad pin and brake pads 4. • Connect the transparent hose 5 to the bleed screw 6 and place the suitable con- tainer under its end.
• Page 81
  INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT • Install the pad pin plug 0. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC- TION” section. 4.
• Page 82
  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 83
  INSP REAR BRAKE PAD INSULATOR INSPECTION/ BRAKE FLUID LEVEL INSPECTION 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC- TION” section. 4. Check: • Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEED- ING”…
• Page 84
  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. Measure: • Drive chain length (15 links) a Out of specification →…
• Page 85
  INSP DRIVE CHAIN SLACK ADJUSTMENT 4. Check: • Drive chain stiffness a Clean and oil the drive chain and hold as illustrated. Stiff → Replace drive chain. 5. Install: • Drive chain 1 • Joint 2 • Master link clip 3 CAUTION: Be sure to install the master link clip to the direction as shown.
• Page 86
  INSP FRONT FORK INSPECTION 3. Adjust: • Drive chain slack Drive chain slack adjustment steps: • Loosen the axle nut 1 and locknuts 2. • Adjust the drive chain slack by turning the adjusters 3. To tighten → Turn the adjuster 3 coun- terclockwise.
• Page 87
  FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ INSP FRONT FORK INTERNAL PRESSURE RELIEVING/ FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1. Remove: • Protector • Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.
• Page 88
  INSP FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT Extent of adjustment Maximum Minimum Fully turned in 20 clicks out (from position maximum position) • STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.

• Page 89: Rear Shock Absorber Inspection

  INSP REAR SHOCK ABSORBER INSPECTION Extent of adjustment Maximum Minimum 20 clicks out Fully turned in (from maximum position position) • STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.

• Page 90
  INSP REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Remove: • Rear frame 3. Loosen: • Locknut 1 4. Adjust: • Spring preload By turning the adjuster 2.
• Page 91
  INSP REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: • Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damp- ing force. (Turn the adjuster 1 in.) Softer b →…
• Page 92
  INSP REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • Low compression damping force By turning the adjuster 1. Stiffer a → Increase the low compres- sion damping force. (Turn the adjuster 1 in.) Softer b →…
• Page 93
  INSP REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • High compression damping force By turning the adjuster 1. Stiffer a → Increase the high compres- sion damping force. (Turn the adjuster 1 in.) Softer b →…
• Page 94
  INSP TIRE PRESSURE CHECK/SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm , 15 psi) NOTE: • Check the tire while it is cold. •…
• Page 95
  INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: • Bearing free play Exist play → Replace. EC36U013 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Check: • Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth.
• Page 96
  INSP STEERING HEAD INSPECTION AND ADJUSTMENT • Tighten the steering ring nut 3 using steering nut wrench 4. NOTE: • Apply the lithium soap base grease on the thread of the steering stem. • Set the torque wrench to the steering nut wrench so that they form a right angle.
• Page 97
  INSP STEERING HEAD INSPECTION AND ADJUSTMENT Steering stem nut: 145 Nm (14.5 m • kg, 105 ft • lb) Handlebar upper holder: 28 Nm (2.8 m • kg, 20 ft • lb) Pinch bolt (upper bracket): 23 Nm (2.3 m • kg, 17 ft • lb) Number plate: 7 Nm (0.7 m •…
• Page 98
  INSP LUBRICATION LUBRICATION È Use Yamaha cable lube or equivalent on these areas. To ensure smooth operation of all compo- É Use SAE 10W-30 motor oil or suitable chain nents, lubricate your machine during setup, lubricants. after break-in, and after every race.

• Page 99: Electrical

  INSP ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: • Spark plug 2. Inspect: • Electrode 1 Wear/damage → Replace. • Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition.

• Page 100
  INSP IGNITION TIMING CHECK IGNITION TIMING CHECK 1. Remove: • Timing mark accessing screw 1 2. Attach: • Timing light • Inductive tachometer To the ignition coil lead (orange lead 1). Timing light: YM-33277-A/90890-03141 3. Adjust: • Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT”…

• Page 101: Seat, Fuel Tank And Side Covers

  SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE SEAT, FUEL TANK AND SIDE COVERS Extent of removal: 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Number plate removal Extent of removal Order Part name Q’ty Remarks SEAT, FUEL TANK AND SIDE COVERS REMOVAL Preparation for removal…

• Page 102
  SEAT, FUEL TANK AND SIDE COVERS REMOVAL POINTS Side cover 1. Remove: • Bolt (side cover) • Left side cover 1 • Right side cover 2 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air fil- ter case.

• Page 103: Exhaust Pipe And Silencer

  EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER È Except for USA Extent of removal: 1 Silencer removal 2 Exhaust pipe removal Extent of removal Order Part name Q’ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS”…

• Page 104
  EXHAUST PIPE AND SILENCER INSPECTION Silencer and exhaust pipe 1. Inspect: • Gasket 1 Damage → Replace. ASSEMBLY AND INSTALLATION Silencer and exhaust pipe 1. Install: • Gasket • Exhaust pipe 1 • Nut (exhaust pipe) 2 13 Nm (1.3 m · kg, 9.4 ft · lb) •…

• Page 105: Radiator

  RADIATOR EC450001 RADIATOR Extent of removal: 1 Radiator removal Extent of removal Order Part name Q’ty Remarks RADIATOR REMOVAL Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”…

• Page 106
  RADIATOR EC456000 HANDLING NOTE WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radi- ator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter-…
• Page 107
  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 DIAGRAM” section in the CHAPTER 2. 4. Install: • Left radiator 1 •…

• Page 108: Carburetor

  CARBURETOR CARBURETOR 4 Nm (0.4 m kg, 2.9 ft • • 2 Nm (0.2 m kg, 1.4 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 3 Nm (0.3 m kg, 2.2 ft •…

• Page 109
  CARBURETOR EC468000 CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Float chamber Leak jet…
• Page 110
  CARBURETOR Extent of removal Order Part name Q’ty Remarks Main jet Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger 4 — 10…
• Page 111
  CARBURETOR HANDLING NOTE CAUTION: Do not loosen the screws (throttle position sensor) 1 except when changing the throt- tle position sensor due to failure because it will cause a drop in engine performance. REMOVAL POINTS Pilot screw 1. Remove: • Pilot screw 1 NOTE: To optimize the fuel flow at a small throttle opening, each machine’s pilot screw has been…
• Page 112
  CARBURETOR 2. Inspect: • Main jet 1 • Pilot jet 2 • Needle jet 3 • Starter jet 4 • Pilot air jet 5 • Leak jet 6 Damage → Replace. Contamination → Clean. NOTE: • Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air.
• Page 113
  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 114
  CARBURETOR Starter plunger 1. Inspect: • Cold starter plunger 1 • Hot starter plunger 2 Wear/damage → Replace. Accelerator pump 1. Inspect: • Diaphragm (accelerator pump) 1 • Spring (accelerator pump) 2 • Accelerator pump cover 3 • O-ring 4 •…
• Page 115
  CARBURETOR 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. 4. Install: • Spring 2 1 To lever 2 2. 5.
• Page 116
  CARBURETOR 8. Install: 1 2 3 • Throttle shaft assembly 1 • Washer (metal) 2 • Washer (resin) 3 • Valve lever 4 NOTE: • Apply the fluorochemical grease on the bear- ings. • Fit the projection a on the throttle shaft assembly into the slot b in the throttle posi- tion sensor.
• Page 117
  CARBURETOR 11. Install: • Needle valve 1 • Float 2 • Float pin 3 NOTE: • After installing the needle valve to the float, install them to the carburetor. • Check the float for smooth movement. 12. Install: • Pilot screw 1 •…
• Page 118
  CARBURETOR 15. Install: • Jet needle 1 • Collar 2 • Spring 3 • Needle holder 4 • Throttle valve plate 5 To throttle valve 6. 16. Install: • Throttle valve assembly 1 • Screw (throttle shaft) 2 NOTE: Install the valve lever rollers 3 into the slits a of the throttle valve.
• Page 119
  CARBURETOR • Fully turn in the accelerator pump adjust- ing screw 3. • Check that the link lever 4 has free play b by pushing lightly on it. • Gradually turn out the adjusting screw while moving the link lever until it has no more free play.
• Page 120
  CARBURETOR 5. Install: • Throttle cable (pull) 1 4 Nm (0.4 m · kg, 2.9 ft · lb) • Throttle cable (return) 2 11 Nm (1.1 m · kg, 8.0 ft · lb) 6. Adjust: • Throttle grip free play Refer to “THROTTLE CABLE ADJUST- MENT”…

• Page 121: Camshafts

  CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER Extent of removal: 1 Cylinder head cover removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Carburetor Refer to “CARBURETOR”…

• Page 122
  CAMSHAFTS CAMSHAFTS Extent of removal: 1 Camshaft removal Extent of removal Order Part name Q’ty Remarks CAMSHAFTS REMOVAL Timing mark accessing screw Crankshaft end accessing screw Timing chain tensioner cap bolt Timing chain tensioner Refer to “REMOVAL POINTS”. Camshaft cap Clip Exhaust camshaft Intake camshaft…
• Page 123
  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. • 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 124
  CAMSHAFTS 5. Remove: • Exhaust camshaft 1 • Intake camshaft 2 NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. INSPECTION Camshaft 1. Inspect: • Cam lobe → Pitting/scratches/blue discoloration Replace. 2. Measure: •…
• Page 125
  CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clearance: 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: • Install the camshaft onto the cylinder head. ® •…
• Page 126
  CAMSHAFTS Decompression system 1. Check: • Decompression system Checking steps: • Check that the decompression mecha- nism cam 1 moves smoothly. • Check that the decompression mecha- nism cam lever pin 2 projects from the camshaft. Timing chain tensioner 1. Check: •…
• Page 127
  CAMSHAFTS • Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. NOTE: The camshafts should be installed onto the cylinder head so that the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface, as shown in the illustration.
• Page 128
  CAMSHAFTS • With the rod fully wound and the chain ten- sioner UP mark a facing upward, install the gasket 1 and the timing chain ten- sioner 2, and tighten the bolt 3 to the specified torque. Bolt (timing chain tensioner): 10 Nm (1.0 m •…
• Page 129
  NOTE: Apply the sealant on the cylinder head cover gasket. Quick gasket ® ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 7. Install: • Oil tank breather hose • Cylinder head breather hose • Spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb)

• Page 130: Cylinder Head

  CYLINDER HEAD CYLINDER HEAD Extent of removal: 1 Cylinder head removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER”…

• Page 131
  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 damag- ing or scratching: • Spark plug threads • Valve seats 2. Inspect: •…
• Page 132
  CYLINDER HEAD ASSEMBLY AND INSTALLATION Cylinder head 1. Install: • Dowel pin 1 • Cylinder head gasket 2 • Timing chain guide (exhaust side) 3 • Cylinder head 4 NOTE: While pulling up the timing chain, install the timing chain guide (exhaust side) and cylinder head.

• Page 133: Valves And Valve Springs

  VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Extent of removal: 1 Valve removal Extent of removal Order Part name Q’ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Valve lifter Use special tool. Adjusting pad Refer to “REMOVAL POINTS”.

• Page 134
  VALVES AND VALVE SPRINGS REMOVAL POINTS Valve lifter and valve cotter 1. Remove: • Valve lifter 1 • Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2.
• Page 135
  VALVES AND VALVE SPRINGS INSPECTION Valve 1. Measure: • Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.003 in) Exhaust:…
• Page 136
  VALVES AND VALVE SPRINGS Valve guide remover: Intake: 4.0 mm (0.16 in) YM-4111/90890-04111 Exhaust: 4.5 mm (0.18 in) YM-4116/90890-04116 Valve guide installer: Intake: 4.0 mm (0.16 in) YM-4112/90890-04112 Exhaust: 4.5 mm (0.18 in) YM-4117/90890-04117 Valve guide reamer: Intake: 4.0 mm (0.16 in) YM-4113/90890-04113 Exhaust: 4.5 mm (0.18 in) YM-4118/90890-04118…
• Page 137
  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 138
  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 139
  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>: 36.81 mm (1.45 in) Exhaust: 37.54 mm (1.48 in) <Limit>: 36.54 mm (1.44 in) 2.
• Page 140
  VALVES AND VALVE SPRINGS ASSEMBLY AND INSTALLATION Valve and valve spring 1. Apply: • Molybdenum disulfide oil Onto the valve stem and valve stem seal. 2. Install: • Valve 1 • Valve spring seat 2 • Valve stem seal 3 •…
• Page 141
  VALVES AND VALVE SPRINGS 5. Install: • Adjusting pad 1 • Valve lifter 2 NOTE: • Apply the molybdenum disulfide oil on the valve stem end. • Apply the engine oil on the valve lifters. • Valve lifter must turn smoothly when rotated with a finger.

• Page 142: Cylinder And Piston

  CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: 1 Cylinder removal 2 Piston removal Extent of removal Order Part name Q’ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Bolt (cylinder) Cylinder Piston pin clip Piston pin Use special tool.

• Page 143
  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 144
  CYLINDER AND PISTON 77.00 ~ 77.01 mm Cylinder bore “C” (3.0315 ~ 3.0319 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = Maximum D “T” = (Maximum D or D – (Maximum D or D “R”…
• Page 145
  CYLINDER AND PISTON Piston ring 1. Measure: • Ring side clearance Use a feeler gauge 1. Out of specification → Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance: Standard <Limit>…
• Page 146
  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 147
  CYLINDER AND PISTON 2. Position: • Top ring • 2nd ring • Oil ring Offset the piston ring end gaps as shown. Top ring end 2nd ring end Oil ring end (upper) Oil ring Oil ring end (lower) 3. Install: •…
• Page 148
  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 149: Clutch

  CLUTCH EC4A0000 CLUTCH Extent of removal: 1 Push rod 1, 2 and push lever shaft removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Primary driven gear removal Extent of removal Order Part name Q’ty Remarks CLUTCH REMOVAL Preparation for removal…

• Page 150
  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 151
  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. È É Clutch holding tool: YM-91042/90890-04086 È…
• Page 152
  CLUTCH Friction plate 1. Measure: • Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness: 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) <Limit>: 2.7 mm (0.106 in) EC484600 Clutch plate 1.
• Page 153
  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 154
  CLUTCH 3. Bend the lock washer 1 tab. 4. Install: • Seat plate 1 • Cushion spring 2 NOTE: • Install the seat plate with its chamfered por- tion a facing the clutch boss 3. • Install the seat plate so that it is not caught on the step b.
• Page 155
  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 •…

• Page 156: Oil Filter Element, Water Pump And Right Crankcase Cover

  OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal: 1 Oil filter element removal 2 Water pump removal 3 Right crankcase cover removal Extent of removal Order Part name Q’ty Remarks OIL FILTER ELEMENT, WATER…

• Page 157
  OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal Order Part name Q’ty Remarks Water pump housing Oil delivery pipe Bolt (oil hose) Kickstarter crank Right crankcase cover Impeller Washer Impeller shaft Refer to “REMOVAL POINTS”. Oil seal Bearing 4 — 57…
• Page 158
  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 159
  OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER EC444200 Impeller shaft 1. Inspect: • Impeller shaft 1 Bend/wear/damage → Replace. Fur deposits → Clean. EC444300 Impeller shaft gear 1. Inspect: • Gear teeth a Wear/damage → Replace. EC4H4600 Bearing 1.
• Page 160
  OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 2. Install: • Bearing 1 NOTE: Install the bearing by pressing its outer race parallel. Impeller shaft 1. Install: • Impeller shaft 1 • Washer 2 • Impeller 3 14 Nm (1.4 m · kg, 10 ft · lb) NOTE: •…
• Page 161
  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 162
  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 163: Balancer

  BALANCER BALANCER Extent of removal: 1 Balancer shaft drive gear 2 Balancer shaft Extent of removal Order Part name Q’ty Remarks BALANCER REMOVAL Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK- CASE COVER”…

• Page 164
  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 165
  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 166: Oil Pump

  OIL PUMP OIL PUMP Extent of removal: 1 Oil pump removal 2 Oil pump disassembly Extent of removal Order Part name Q’ty Remarks OIL PUMP REMOVAL AND DIS- ASSEMBLY Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK- CASE COVER”…

• Page 167
  OIL PUMP Extent of removal Order Part name Q’ty Remarks Dowel pin Washer Oil pump drive shaft Rotor housing 4 — 67…
• Page 168
  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) •…
• Page 169
  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 170
  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) •…

• Page 171: Kick Shaft And Shift Shaft

  KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT Extent of removal: 1 Kick shaft removal 2 Kick shaft disassembly 3 Shift shaft removal 4 Segment removal Extent of removal Order Part name Q’ty Remarks KICK SHAFT AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump…

• Page 172
  KICK SHAFT AND SHIFT SHAFT Extent of removal Order Part name Q’ty Remarks Torsion spring Roller Shift guide Refer to “REMOVAL POINTS”. Shift lever assembly Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to “REMOVAL POINTS”. 4 — 72…
• Page 173
  KICK SHAFT AND SHIFT SHAFT REMOVAL POINTS Kick shaft assembly 1. Remove: • Kick shaft assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1. Remove: • Bolt (shift guide) •…
• Page 174
  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 •…
• Page 175
  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 176
  KICK SHAFT AND SHIFT SHAFT 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. 2. Install: • Shift pedal 1 •…
• Page 177
  KICK SHAFT AND SHIFT SHAFT 3. Install: • Spring guide 1 NOTE: Slide the spring guide into the kick shaft, make sure the groove a in the spring guide fits on the stopper of the torsion spring. 4. Install: • Kick shaft assembly 1 •…

• Page 178: Cdi Magneto

  CDI MAGNETO EC4L0000 CDI MAGNETO Extent of removal: 1 CDI magneto removal Extent of removal Order Part name Q’ty Remarks CDI MAGNETO REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Bolt (left radiator) Refer to “RADIATOR”…

• Page 179
  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: YM-1189/90890-01189 NOTE: When installing the flywheel puller, turn it counterclockwise.
• Page 180
  • 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 181
  CDI MAGNETO 4. Connect: • CDI magneto lead Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 5. Install: • Dowel pin • Gasket (left crankcase cover) • Left crankcase cover 1 • Hose guide (cylinder head breather hose) •…

• Page 182: Engine Removal

  ENGINE REMOVAL EC4M0000 ENGINE REMOVAL Extent of removal Order Part name Q’ty Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the WARNING suitable stand under the frame. Support the machine securely so there is no danger of it falling over. Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”…

• Page 183
  ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Order Part name Q’ty Remarks Ignition coil Disconnect the CDI magneto lead. Right engine guard Lower engine guard Neutral switch Bolt (oil hose) Drive chain sprocket cover Nut (drive sprocket) Lock washer Refer to “REMOVAL POINTS”.
• Page 184
  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 •…

• Page 185: Engine Installation

  ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1. Install: • Engine 1 Install the engine from right side. • Pivot shaft 2 85 Nm (8.5 m · kg, 61 ft · lb) • Engine mounting bolt (lower) 3 69 Nm (6.9 m · kg, 50 ft · lb) •…

• Page 186
  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 187: Crankcase And Crankshaft

  CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal: 1 Crankcase separation 2 Crankshaft removal Extent of removal Order Part name Q’ty Remarks CRANKCASE AND CRANK- SHAFT REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON” sec- tion.

• Page 188
  CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q’ty Remarks Bolt [L = 45 mm (1.77 in)] Bolt [L = 55 mm (2.17 in)] Bolt [L = 70 mm (2.76 in)] Hose guide Refer to “REMOVAL POINTS”. Clutch cable holder Right crankcase Left crankcase Oil strainer…
• Page 189
  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 CAM AND SHIFT FORK” section. Shift cam and shift fork Oil seal Bearing Refer to “REMOVAL POINTS”.
• Page 190
  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 191
  CRANKCASE AND CRANKSHAFT Crankshaft 1. Remove: • Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 CAUTION: Do not use a hammer to drive out the crankshaft. Crankcase bearing 1. Remove: • Bearing 1 NOTE: • Remove the bearing from the crankcase by pressing its inner race.
• Page 192
  CRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1. Measure: • Runout limit a • Small end free play limit b • Connecting rod big end side clearance c • Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge.
• Page 193
  CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankcase bearing 1. Install: • Bearing • Bearing stopper • Bolt (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) • Screw (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) •…
• Page 194
  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 195
  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 196: Transmission, Shift Cam And Shift Fork

  TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: 1 Shift fork, shift cam, main axle and drive axle removal Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL”…

• Page 197
  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 198
  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 199
  TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: • 2nd wheel gear (28T) 1 • 4th wheel gear (27T) 2 • 3rd wheel gear (29T) 3 • 5th wheel gear (25T) 4 • 1st wheel gear (30T) 5 • O-ring 6 To drive axle 7.
• Page 200
  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 201: Chassis

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

• Page 202
  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 Support the machine securely so suitable stand under the engine.
• Page 203
  CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: • Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 NOTE: Remove the bearing using a general bearing puller 2.
• Page 204
  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 205
  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 206
  CHAS FRONT WHEEL AND REAR WHEEL 5. Install: • Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. 6. Install: • Nut (wheel axle) 1 105 Nm (10.5 m · kg, 75 ft · lb) 7.
• Page 207
  CHAS FRONT WHEEL AND REAR WHEEL 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 208
  CHAS FRONT WHEEL AND REAR WHEEL 4. Install: • Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip. 5. Install: • Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly. 6. Install: •…
• Page 209
  CHAS FRONT WHEEL AND REAR WHEEL 9. Adjust: • Drive chain slack a Drive chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in) Refer “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAPTER 10. Tighten: • Nut (wheel axle) 1 125 Nm (12.5 m ·…

• Page 210: Front Brake And Rear Brake

  CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 2 Brake caliper removal 3 Brake master cylinder removal Extent of removal Order Part name Q’ty Remarks FRONT BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the…

• Page 211: Rear Brake

  CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE Extent of removal: 1 Brake master cylinder removal 2 Brake hose removal 3 Brake caliper removal Extent of removal Order Part name Q’ty Remarks REAR BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so suitable stand under the engine.

• Page 212
  CHAS FRONT BRAKE AND REAR BRAKE BRAKE CALIPER DISASSEMBLY È Front É Rear Extent of removal: 1 Front brake caliper disassembly 2 Rear brake caliper disassembly Extent of removal Order Part name Q’ty Remarks BRAKE CALIPER DISASSEM- Pad pin Brake pad Pad support Brake caliper piston Dust seal…
• Page 213
  CHAS FRONT BRAKE AND REAR BRAKE BRAKE MASTER CYLINDER DISASSEMBLY È Front É Rear Extent of removal: 1 Front brake master cylinder disassembly 2 Rear brake master cylinder disassembly Extent of removal Order Part name Q’ty Remarks BRAKE MASTER CYLINDER DISASSEMBLY Brake master cylinder cap Diaphragm…
• Page 214
  CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 È REMOVAL POINTS Brake fluid 1. Remove: [Front] • Brake master cylinder cap 1 [Rear] • Brake master cylinder cap 1 • Protector NOTE: Do not remove the diaphragm. É È Front É Rear 2.
• Page 215
  CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston seal kit È 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 É…
• Page 216
  CHAS FRONT BRAKE AND REAR BRAKE 4. Inspect: È É • Brake master cylinder piston 1 • Brake master cylinder cup 2 Wear/damage/score marks → Replace brake master cylinder kit. È Front É Rear Brake caliper È É 1. Inspect: •…
• Page 217
  CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston È 1. Clean: • Brake caliper • Piston seal • Dust seal • Brake caliper piston Clean them with brake fluid. 2. Install: • Piston seal 1 • Dust seal 2 É…
• Page 218
  CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake caliper 1 • Bolt (brake caliper) 2 23 Nm (2.3 m · kg, 17 ft · lb) 3. Tighten: • Pad pin 3 18 Nm (1.8 m · kg, 13 ft · lb) 4.
• Page 219
  CHAS FRONT BRAKE AND REAR BRAKE 3. Install: • Brake caliper 1 • Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section. 4. Tighten: • Pad pin 3 18 Nm (1.8 m · kg, 13 ft · lb) 5.
• Page 220
  CHAS FRONT BRAKE AND REAR BRAKE 4. Install: È [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 •…
• Page 221
  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 222
  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 223
  CHAS FRONT BRAKE AND REAR BRAKE 4. Pass the brake hose through the cable guide 1. 5. Install: • Copper washer 1 • Brake hose 2 • Union bolt 3 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers.
• Page 224
  CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake hose holder 1 • Screw (brake hose holder) 2 1 Nm (0.1 m · kg, 0.7 ft · lb) CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber).
• Page 225
  CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: • Brake system Refer to “BRAKE SYSTEM AIR BLEED- ING” section in the CHAPTER 3. 3. Inspect: • Brake fluid level Fluid at lower level → Fill up. Refer to “BRAKE FLUID LEVEL INSPEC- TION”…

• Page 226: Front Fork

  CHAS FRONT FORK EC550000 FRONT FORK Extent of removal: 1 Front fork removal Extent of removal Order Part name Q’ty Remarks FRONT FORK REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.

• Page 227: Front Fork Disassembly

  CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY Extent of removal: 1 Oil seal removal 2 Damper assembly removal Extent of removal Order Part name Q’ty Remarks FRONT FORK DISASSEMBLY Adjuster Drain the fork oil. Use special tool. Refer to “REMOVAL POINTS”. Fork spring Dust seal Stopper ring…

• Page 228
  CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. CAUTION: To prevent an accidental explosion of air, following instructions should observed: • The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to foreign material.
• Page 229
  CHAS FRONT FORK Adjuster 1. Drain the outer tube of its front fork oil at its top. 2. Loosen: • Adjuster 1 3. Remove: • Adjuster 1 NOTE: • While compressing the inner tube 2, set the cap bolt ring wrench 4 between the inner tube and locknut 3.
• Page 230
  CHAS FRONT FORK Base valve 1. Remove: • Base valve 1 From damper assembly 2. NOTE: Hold the damper assembly with the cap bolt ring wrench 3 and use the cap bolt wrench 4 to remove the base valve. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench: YM-01501/90890-01501…
• Page 231
  CHAS FRONT FORK Base valve 1. Inspect: • Base valve 1 Wear/damage → Replace. Contamination → Clean. • O-ring 2 Wear/damage → Replace. • Bushing 3 Wear/damage → Replace base valve. • Spring 4 Damage/fatigue → Replace base valve. • Air bleed screw 5 Wear/damage →…
• Page 232
  CHAS FRONT FORK EC554600 Outer tube 1. Inspect: • Outer tube 1 Score marks/wear/damage → Replace. Adjuster 1. Inspect: • Adjuster 1 • O-ring 2 Wear/damage → Replace. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2.
• Page 233
  CHAS FRONT FORK 4. After filling, pump the damper assembly 1 slowly up and down (about 200 mm (7.9 in) stroke) several times to bleed the damper assembly of air. NOTE: Be careful not to excessive full stroke. A stroke of 200 mm (7.9 in) or more will cause air to enter.
• Page 234
  CHAS FRONT FORK 9. Tighten: • Base valve 1 29 Nm (2.9 m · kg, 21 ft · lb) NOTE: Hold the damper assembly with the cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve with specified torque. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench:…
• Page 235
  CHAS FRONT FORK 13. Check: • Damper assembly smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14. Install: • Dust seal 1 • Stopper ring 2 • Oil seal 3 • Oil seal washer 4 • Slide metal 5 To inner tube 6.
• Page 236
  CHAS FRONT FORK 17. 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 18. Install: • Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2.
• Page 237
  CHAS FRONT FORK 21. Check: • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 14 to 20. 22. Measure: • Distance a Out of specification → Turn into the lock- nut. Distance a: 19 mm (0.75 in) or more Between damper assembly 1 bottom and locknut 2 bottom.
• Page 238
  CHAS FRONT FORK 26. Install: • Push rod 1 • Copper washer 2 • Adjuster 3 To damper assembly 4. NOTE: • While compressing the inner tube 5, set the cap bolt ring wrench 7 between the inner tube and locknut 6. •…
• Page 239
  CHAS FRONT FORK 29. Install: • Adjuster 1 55 Nm (5.5 m · kg, 40 ft · lb) To inner tube. 30. Fill: • Front fork oil 1 From outer tube top. Recommended oil: Suspension oil “S1” Standard oil amount: 245 cm (8.62 Imp oz, 8.28 US oz) Extent of adjustment:…
• Page 240
  CHAS FRONT FORK 32. Install: • Protector guide 1 Installation 1. Install: • Front fork 1 NOTE: • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (upper bracket) yet. 2. Tighten: • Damper assembly 1 30 Nm (3.0 m ·…
• Page 241
  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 242: Handlebar

  CHAS HANDLEBAR EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal Number plate Remove the clamp portion only. Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side.

• Page 243
  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 244
  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 245
  CHAS HANDLEBAR 3. Install: • Right grip 1 • Collar 2 Apply the adhesive on the tube guide 3. NOTE: • Before applying the adhesive, wipe off grease or oil on the tube guide surface a with a lacquer thinner. •…
• Page 246
  CHAS HANDLEBAR 6. Install: • Throttle cable cap 1 • Screw (throttle cable cap) 2 4 Nm (0.4 m · kg, 2.9 ft · lb) WARNING After tightening the screws, check that the throttle grip 3 moves smoothly. If it does not, retighten the bolts for adjustment.
• Page 247
  CHAS HANDLEBAR 9. Install: • Engine stop switch 1 • Clutch lever holder 2 • Bolt (clutch lever holder) 3 4 Nm (0.4 m · kg, 2.9 ft · lb) • Hot starter lever holder 4 • Bolt (hot starter lever holder) 5 4 Nm (0.4 m ·…

• Page 248: Steering

  CHAS STEERING EC560000 STEERING Extent of removal: 1 Lower bracket removal 2 Bearing removal Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so suitable stand under the engine. there is no danger of it falling over.

• Page 249
  CHAS STEERING EC563000 REMOVAL POINTS Steering ring nut 1. Remove: • Steering ring nut 1 Use the steering nut wrench 2. Steering nut wrench: YU-33975/90890-01403 WARNING Support the steering stem so that it may not fall down. Lower bearing 1. Remove: •…
• Page 250
  CHAS STEERING Bearing and bearing race 1. Wash the bearings and bearing races with a solvent. 2. Inspect: • Bearing 1 • Bearing race Pitting/damage → Replace bearings and bearing races as a set. Install the bearing in the bearing races. Spin the bearings by hand.
• Page 251
  CHAS STEERING 4. Install: • Steering ring nut 1 7 Nm (0.7 m · kg, 5.1 ft · lb) Tighten the steering ring nut using the steering nut wrench 2. Refer to “STEERING HEAD INSPEC- TION AND ADJUSTMENT” section in the CHAPTER 3.
• Page 252
  CHAS STEERING 9. Install: • Steering stem cap 1 10. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little. 11. Adjust: • Front fork top end a Front fork top end (standard) a: 5 mm (0.20 in) 12.

• Page 253: Swingarm

  CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal Extent of removal Order Part name Q’ty Remarks SWINGARM REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so suitable stand under the engine. there is no danger of it falling over.

• Page 254
  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 Refer to “REMOVAL POINTS”. Relay arm Connecting rod Collar Oil seal Thrust bearing…
• Page 255
  CHAS SWINGARM EC573000 REMOVAL POINTS 1. Remove: • Left cap 1 NOTE: Remove with a slotted-head screwdriver inserted under the mark a on the left cap. EC573200 Bearing 1. Remove: • Bearing 1 NOTE: Remove the bearing by pressing its outer race. INSPECTION Wash the bearings, bushings, collars, and cov- ers in a solvent.
• Page 256
  CHAS SWINGARM Connecting rod 1. Inspect: • Bearing 1 • Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal 3 Damage → Replace. EC575000 ASSEMBLY AND INSTALLATION Bearing and oil seal 1.
• Page 257
  CHAS SWINGARM 3. Install: • Bearing 1 • Oil seal 2 To connecting rod. 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. Installed depth of bearings a: 5 mm (0.20 in) Swingarm…
• Page 258
  CHAS SWINGARM 3. Install: • Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: • Connecting rod 1 • Bolt (connecting rod) 2 • Washer 3 • Nut (connecting rod) 4 80 Nm (8.0 m ·…
• Page 259
  CHAS SWINGARM 8. Install: • Bolt (connecting rod) 1 • Washer 2 • Nut (connecting rod) 3 NOTE: • Apply the molybdenum disulfide grease on the bolt. • Do not tighten the nut yet. 9. Install: • Bolt (rear shock absorber-relay arm) 1 •…
• Page 260
  CHAS SWINGARM 13. Install: • Bolt (lower chain tensioner) 1 • Washer 2 • Collar 3 • Lower chain tensioner 4 • Nut (lower chain tensioner) 5 20 Nm (2.0 m · kg, 14 ft · lb) 14. Install: • Drive chain support 1 •…

• Page 261: Rear Shock Absorber

  CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER Extent of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal Order Part name Q’ty Remarks REAR SHOCK ABSORBER WARNING REMOVAL Support the machine securely so Preparation for removal Hold the machine by placing the there is no danger of it falling over.

• Page 262
  CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q’ty Remarks Upper spring guide Spring (rear shock absorber) Bearing Refer to “REMOVAL POINTS”. 5 — 62…
• Page 263
  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 — 63…
• Page 264
  CHAS REAR SHOCK ABSORBER EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: • Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: • Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3.
• Page 265
  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 266
  CHAS REAR SHOCK ABSORBER 2. Tighten: • Adjuster 1 3. Adjust: • Spring length (installed) a Spring length (installed) a: Extent of Standard length adjustment 250.5 mm (9.86 in) 240.5 ~ 258.5 mm * 248.5 mm (9.78 in) (9.47 ~ 10.18 in) * For EUROPE NOTE: The length of the spring (installed) changes…
• Page 267
  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. •…

• Page 268: Electrical Components And Wiring Diagram

  ELEC – ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS COLOR CODE 1 Engine stop switch B…… Black W …..White 2 Throttle position sensor Br ….Brown Y ……Yellow 3 Neutral switch G …..

• Page 269: Map-Controlled Cdi Unit

  MAP-CONTROLLED CDI UNIT MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the YZ250F. 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 270: Ignition System

  ELEC – IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark *Clean or replace Spark gap test spark plug.

• Page 271
  ELEC – IGNITION SYSTEM SPARK GAP TEST È 1. Disconnect the spark plug cap from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (igni- tion checker 2) as shown. • Ignition coil 3 •…
• Page 272
  ELEC – IGNITION SYSTEM EC626002 IGNITION COIL INSPECTION 1. Inspect: • Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Black lead 2 Primary coil Tester selector resistance position 0.08 ~ 0.10 Ω at Ω…
• Page 273
  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 720 ~ 1,080 Ω Ω…

• Page 274: Throttle Position Sensor System

  ELEC – THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. No good Check entire ignition Repair or replace. system for connection. No good Check throttle position Throttle posi- Replace.

• Page 275
  ELEC – THROTTLE POSITION SENSOR SYSTEM 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. EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1.
• Page 276
  ELEC – THROTTLE POSITION SENSOR SYSTEM 3. Inspect: • Throttle position sensor coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position. Out of specification → Replace. Tester (+) lead →…
• Page 277
  ELEC – THROTTLE POSITION SENSOR SYSTEM 4. Install: • Throttle position sensor coupler 5. Adjust: • Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT” section in the CHAPTER 6. Insert the thin electric conductors 2 (lead) into the throttle position sensor coupler 1, as shown, and connect the tester to them.
• Page 278
  ELEC – THROTTLE POSITION SENSOR SYSTEM 9. Tighten: • Screw (throttle position sensor) 1 NOTE: Tighten the screws (throttle position sensor) using the T25 bit. 10. Stop the engine. THROTTLE POSITION SENSOR INPUT VOLTAGE INSPECTION 1. Disconnect the throttle position sensor cou- pler.

• Page 279: Tuning

  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 280
  T U N SETTING CAUTION: • The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. • Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carburetor parts may prevent the carburetor from…
• Page 281
  T U N SETTING Effects of the setting parts on the throttle valve opening È É È Closed É Fully open 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet Main system The FLATCR carburetor has a primary main jet.
• Page 282
  T U N SETTING 1 Jet needle 2 Pilot air jet 3 Needle jet 4 Main jet 5 Pilot jet 6 Pilot screw Main jet adjustment The richness of the air-fuel mixture at full throt- tle can be set by changing the main jet 1. Standard main jet #182 If the air-fuel mixture is too rich or too lean, the…
• Page 283
  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 284
  T U N SETTING Effects of adjusting the pilot jet (reference) È É –5% È Idle É 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 285
  T U N SETTING Jet needle adjustment The jet needle is adjusted by changing it. OBELR Standard jet needle * OBEKS * Except for USA The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters.
• Page 286
  T U N SETTING Leak jet adjustment (accelerator pump adjustment) The leak jet 1 is a setting part that adjusts the flow of fuel discharged by the accelerator pump. Since the accelerator pump operates only when throttle is open, the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is therefore different from other setting parts that adjust a fuel mixture for each…
• Page 287
  T U N SETTING EC71Q000 Carburetor setting parts Part name Size Part number Main jet Rich #192 4MX-14943-96 #190 4MX-14943-45 #188 4MX-14943-95 #185 4MX-14943-44 (STD) #182 4MX-14943-94 #180 4MX-14943-43 #178 4MX-14943-93 #175 4MX-14943-42 Lean #172 4MX-14943-92 Pilot jet Rich 4MX-14948-06 4MX-14948-05 (STD) 4MX-14948-04…
• Page 288
  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 Clogged float valve seat…

• Page 289: Chassis

  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 48/13 (3.692) reduction ratio *49/13 (3.769) * For EUROPE <Requirement for selection of secondary gear reduction ratio>…

• Page 290
  T U N SETTING Drive and rear wheel sprockets setting parts Part name Size Part number Drive sprocket 1 (STD) 9383B-13218 Rear wheel 1C3-25447-00 sprocket 2 (STD) 1C3-25448-00 * (STD) 1C3-25449-00 1C3-25450-00 1C3-25451-00 1C3-25452-00 * For EUROPE EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit.
• Page 291
  T U N SETTING Front fork setting The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics •…
• Page 292
  T U N SETTING Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the spacer 2 and fork spring 3. CAUTION: Do not install three or more adjustment washers for each front fork. WARNING Always adjust each front fork to the same setting.
• Page 293
  T U N SETTING 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. To set a stiff spring: •…
• Page 294
  T U N SETTING Front fork setting parts • Adjustment washer 1 TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 1C3-23364-00 • Front fork spring 2 I.D. SPRING SPRING PART TYPE MARK RATE NUMBER (slits) 0.398 1C3-23141-00 0.408 1C3-23141-10 SOFT 0.418…
• Page 295
  T U N SETTING EC72C001 Choosing set length 1. Place a stand or block under the engine to put the rear wheel above the floor, and measure the length a between the rear wheel axle center and the rear fender hold- ing bolt.
• Page 296
  T U N SETTING Setting of spring after replacement After replacement, be sure to adjust the spring to the set length [sunken length 90 ~ 100 mm (3.5 ~ 3.9 in)] and set it. 1. Use of soft spring • Set the soft spring for less rebound damping to compensate for its less spring load.
• Page 297
  T U N SETTING EC72Q000 Rear shock absorber setting parts • Rear shock spring 1 [Equal pitch spring] I.D. SPRING TYPE SPRING SPRING COLOR/ FREE RATE PART NUMBER POINT LENGTH 5UN-22212-00 Brown/1 SOFT 5UN-22212-10 Green/1 5UN-22212-20 Red/1 5UN-22212-30 Black/1 5UN-22212-40 Blue/1 5UN-22212-50 Yellow/1…

• Page 298: Suspension Setting

  T U N SETTING EC72H002 Suspension setting • Front fork NOTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. •…

• Page 299
  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 300
  YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.07-2.6×1 CR 2500 SHINGAI IWATA SHIZUOKA JAPAN (E,F,G,H)

Chapters

Troubleshooting

• Page 1
  OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER-UND WARTUNGS-HANDBUCH MANUALE DI SEVIZIO DEL PROPRIETARIO YZ250 ( R ) /LC 5UP-28199-30…
• Page 2
  EC010010 YZ250(R)/LC OWNER’S SERVICE MANUAL ©2002 by Yamaha Motor Co., Ltd. 1st Edition, May 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan…
• Page 3
  FAHRER-UND MANUALE DI SERVIZIO DEL DU PROPRIETAIRE WARTUNGSHANDBUCH PROPRIETARIO ©2002 Yamaha Motor Co.,Ltd. ©2002 der Yamaha Motor Co., Ltd. ©2002 by Yamaha Motor Co., Ltd. 1ère Edition, Mai 2002 1. Ausgabe, Mai 2002 1a Edizione, Mei 2002 Tous droits réservés.
• Page 4
  EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
• Page 5
  Wir möchten Ihnen zum Kauf einer Complimenti per avere acquistato una Yamaha séries YZ. Ce modèle est Yamaha YZ Serie, herzlich gratulie- Yamaha serie YZ. Questo modello è il l’aboutissement de la vaste expérience ren. Dieses Modell entspricht fort- culmine della vasta esperienza della…

• Page 6: Important Notice

  EC040001 IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding.

• Page 7: Wichtige Hinweise

  IC040001 NOTICE IMPORTANTE WICHTIGE HINWEISE NOTA IMPORTANTE CETTE MACHINE EST STRICTE- DIESE MASCHINE IST NUR FÜR QUESTO VEICOLO È PROGETTA- MENT DESTINEE A LA COMPETI- RENNEN AUF GESCHLOSSENEN TO PER ESSERE USATO RIGORO- TION, UNIQUEMENT SUR CIRCUIT KURSEN KONSTRUIERT. ES VER- SAMENTE IN GARA, SOLTANTO FERME.

• Page 8
  5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refuel- ing. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking. 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, con-…
• Page 9
  5. L’ESSENCE EST HAUTE- 5. LA BENZINA È ALTAMEN- 5. BENZIN IST BRENNBAR. MENT INFLAMMABLE. TE INFIAMMABILE. Immer den Motor abstellen, Toujours arrêter le moteur en Spegnere sempre il motore bevor aufgetankt wird. Dar- faisant le plein. Faire attention durante il rifornimento di car- auf achten, daß…
• Page 10
  Some data in this manual may become out- dated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer. EC070001 F.I.M. MACHINE WEIGHTS:…
• Page 11
  SECONDO LA F.I.M.: Maschine auftauchen sollten, wen- Poids des machines sans carbu- Pesi dei veicoli senza carburante den Sie sich bitte an Ihren Yamaha rant I pesi minimi per i veicoli per moto- Fachhändler. Les poids minimum admis pour les cross sono: GEWICHT DER F.I.M.

• Page 12: Description

  EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT IN FORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! 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: Chapitre

  IC080000 COMMENT VERWENDUNG COME USARE IL UTILISER CE DIESER ANLEITUNG PRESENTE MANUEL MANUALE IC081000 INFORMATIONS WICHTIGE INFORMATION INFORMAZIONI PARTICULIEREMENT PARTICOLARMENTE Sicherheitssymbol bedeutet IMPORTANTES IMPORTANTI „AUFPASSEN“! VORSICHT GEBOTEN Le symbole d’alerte de sécurité signifie Il Simbolo di Allerta in materia di Sicu- IHRER EIGENEN SICHERHEIT.

• Page 14
  EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., 9 Bearings…
• Page 15
  IC083000 FORMAT DU MANUEL FORMAT DER ANLEITUNG FORMATO DEL Dans ce manuel, toutes les procédures Allen dieser Anleitung enthaltenen MANUALE sont décrites pas à pas. Les informa- Vorgänge sind sequentiell in der Tutte le procedure contenute nel pre- tions ont été condensées pour fournir au durchzuführenden Reihenfolge aufge- sente manuale sono organizzate in for- mécanicien un guide pratique et facile à…
• Page 16
  EC085002 ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC INFO Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. General information INSP Specifications Regular inspection and adjustments Engine Chassis Electrical Tuning CHAS ELEC Illustrated symbols 8 to r are used to identify the specifications appearing in the text.
• Page 17
  IC085002 SYMBOLES GRAPHIQUES ABGEBILDETEN SYMBOLE SIMBOLI ILLUSTRATI (Voir l’illustration) (Siehe Abbildung) (Fare riferimento all’illustra- Les symboles graphiques 1 à 7 ser- Die abgebildeten Symbole 1 bis 7 zione) vent à repérer les différents chapitres et sind zur einfachen Auffindung der Sei- I simboli illustrati da 1 a 7 sono pro- à…
• Page 18
  EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING…
• Page 19
  INDEX IC090010 INDEX INDICE ANALITICO ALLGEMEIN RENSEIGNEMENTS INFORMAZIONI ANGABEN GENERAUX GENERALI INFO TECHINSCHE CARACTERISTIQUES SPECIFICHE DATEN SPEC REGELMÄSSIGE VERIFICATION ET ISPEZIONE E PRÜFUNG REGLAGES REGOLAZIONI INSP COURANTS REGOLARI EINSTELLUNGEN MOTOR MOTEUR MOTORE FAHRGESTELL PARTIE CYCLE TELAIO CHAS ELEKTRISCHE PARTIE PARTE ELETTRICA EINRICHTUNGEN ELECTRIQUE ELEC…

• Page 20: Table Of Contents

  EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION ……….1-1 MACHINE IDENTIFICATION ……1-2 IMPORTANT INFORMATION …..1-3 CHECKING OF CONNECTION ….1-6 SPECIAL TOOLS……..1-7 CONTROL FUNCTIONS……1-9 FUEL AND ENGINE MIXING OIL…..1-12 STARTING AND BREAK-IN …..1-13 TORQUE-CHECK POINTS…….1-16 CLEANING AND STORAGE ….1-17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ….2-1 MAINTENANCE SPECIFICATIONS …2-3 GENERAL TORQUE SPECIFICATIONS..2-12…

• Page 21: Table Of Contents

  IC0A0000 TABLES DES INHALTSVERZEICHNIS INDICE MATIERES CAPITOLO 1 CHAPITRE 1 KAPITEL 1 INFORMAZIONI RENSEIGNEMENTS ALLGEMEIN GENERALI GENERAUX ANGABEN DESCRIPTION ………..1-1 BESCHREIBUNG ……..1-1 DESCRIZIONE ………..1-1 IDENTIFICATION DE LA MACHINE …1-2 MASCHINEN-IDENTIFIKATION….1-2 IDENTIFICAZIONE DEL VEICOLO ..1-2 INFORMATIONS IMPORTANTES ..1-3 WICHTIGE INFORMATIONEN ….1-3 INFORMAZIONI IMPORTANTI…..1-3 VERIFICATION DES CONNEXIONS ..1-6 ANSCHLÜSSE PRÜFEN ……1-6…

• Page 22: Table Of Contents

  CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ………….4-1 EXHAUST PIPE AND SILENCER ….4-3 RADIATOR……….4-4 CARBURETOR AND REED VALVE…4-7 CYLINDER HEAD , CYLINDER AND PISTON ………….4-18 CLUTCH AND PRIMARY DRIVEN GEAR …………4-33 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR……4-40 YPVS GOVERNOR ……..4-49 WATER PUMP ……….4-52 CDI MAGNETO ………4-56…

• Page 23
  CHAPITRE 4 KAPITEL 4 CAPITOLO 4 MOTEUR MOTOR MOTORE SELLE, RESERVOIR A ESSENCE SITZ, KRAFTSTOFFTANK UND SELLA, SERBATOIO DEL ET COUVERCLES LATERAUX….4-1 CARBURANTE E COPERTURE SEITENDECKEL………4-1 LATERALI ……….4-1 TUYAU D’ECHAPPEMENT ET AUSPUFFROHR UND SILENCIEUX ……….4-3 SCHALLDÄMPFER ……..4-3 TUBO DI SCARICO E SILENZIATORE………4-3 RADIATEUR ……….4-4 KÜHLER…………4-4…

• Page 24: Table Of Contents

  CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ……..6-1 IGNITION SYSTEM……..6-2 SOLENOID VALVE SYSTEM …..6-7 TPS (THROTTLE POSITION SENSOR) SYSTEM…………6-9 CHAPTER 7 TUNING ENGINE…………7-1 CHASSIS………..7-13…

• Page 25: Table Of Contents

  CHAPITRE 6 KAPITEL 6 CAPITOLO 6 PARTIE ELEKTRISCHE PARTE ELETTRICA ELECTRIQUE EINRICHTUNGEN COMPOSANTS ELECTRIQUES ELEKTRISCHE BAUTEILE UND COMPONENTI ELETTRICI E SCHEMA ET SCHEMA DE CABLAGE ….6-1 ELETTRICO ……….6-1 SCHALTPLAN ……….6-1 SYSTEME D’ALLUMAGE …….6-2 ZÜNDANLAGE ………..6-2 SISTEMA DI ACCENSIONE ….6-2 SYSTEME D’ELECTROVANNE …..6-7 SISTEMA ELETTROVALVOLA …..6-7 MAGNETVENTILSYSTEM ……6-7 SYSTEME TPS (CAPTEUR DE…

• Page 26: Engine

  DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 NOTE: DESCRIPTION 1 Clutch lever 9 The machine you have purchased may differ 2 “ENGINE STOP” button slightly from those shown in the following. 3 Front brake lever 9 Designs and specifications are subject to 4 Throttle grip change without notice.

• Page 27: Informazioni Generali

  DESCRIPTION BESCHREIBUNG DESCRIZIONE INFO IC100000 RENSEIGNEMENTS ALLGEMEIN INFORMAZIONI GENERAUX ANGABEN GENERALI IC110000 DESCRIPTION BESCHREIBUNG DESCRIZIONE 1 Levier d’embrayage 1 Kupplungshebel 1 Leva di comando della frizione 2 Bouton de coupe-circuit de sécurité 2 Motorstoppknopf „ENGINE STOP“ 2 Pulsante “ARRESTO MOTORE” “ENGINE STOP”…

• Page 28: Machine Identification

  There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive iden- tification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.

• Page 29: Identification De La Machine

  Seriennummer ange- cessionario Yamaha per un’identi- Yamaha qui pourra identifier clai- geben werden, damit Ihr Yamaha ficazione certa del modello posse- rement le modèle correspondant à Fachhändler das Modell richtig duto.

• Page 30: Important Information

  IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DIS ASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pres- sured water, cover the parts as follows. 9 Silencer exhaust port 9 Side cover air intake port 9 Water pump housing hole at the bottom…

• Page 31: Informations Importantes

  INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO IC130000 INFORMATIONS INFORMAZIONI WICHTIGE IMPORTANTES INFORMATIONEN IMPORTANTI IC131010 PREPARATION POUR LA DEPO- VORBEREITUNG FÜR DEN PREPARAZIONE PER LA RIMO- SE ET DEMONTAGE AUSBAU UND DER DEMONTAGE ZIONE E LO SMONTAGGIO 1. Eliminer soigneusement crasse, 1.

• Page 32
  IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended Yamaha assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled.
• Page 33
  Yamaha per tutti i ricambi. Bauteile zu verwenden. Für Ein- les remplacements. Utiliser les Usare olio e/o grasso raccomandati bau und Einstellungen nur das huiles/graisses recommandées par dalla Yamaha per il montaggio e la Yamaha empfohlene Öl Yamaha lors des remontages et regolazione.
• Page 34
  IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is posi- tioned opposite to the thrust 3 it receives. See the sectional view.
• Page 35
  INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO IC136000 CIRCLIPS SICHERUNGSRINGE ANELLI ELASTICI DI ARRESTO 1. Avant remontage, tous les circlips 1. Alle Sicherungsringe vor dem Wie- 1. Si dovrebbero ispezionare attenta- doivent être soigneusement véri- dereinbau gründlich prüfen. Die mente tutti gli anelli elastici di fiés.

• Page 36: Checking Of Connection

  CHECKING OF CONNECTION INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: 9 Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off.

• Page 37: Controllo Dei Collegamenti

  VERIFICATION DES CONNEXIONS ANSCHLÜSSE PRÜFEN CONTROLLO DEI COLLEGAMENTI INFO IC1C0001 VERIFICATION DES ANSCHLÜSSE PRÜFEN CONTROLLO DEI Bei Flecken, Rost, Feuchtigkeit u.ä. CONNEXIONS COLLEGAMENTI auf einem Steckverbinder: Traitement des taches, de la rouille, de Come trattare macchie, ruggine, umi- 1. Lösen: l’humidité, etc.

• Page 38: Special Tools

  SPECIAL TOOLS INFO EC140002 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and part number used for the special tool differ by country, so two types are provid- ed.

• Page 39
  Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the igni- tion system components. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc.

• Page 40: Outils Speciaux

  OUTILS SPECIAUX INFO OUTILS SPECIAUX Les outils spéciaux appropriés sont indispensables pour pouvoir effectuer un assemblage et une mise au point complets et précis. L’utilisation des outils spéciaux corrects permettra d’éviter les endommagements dus à l’emploi d’outils impropres et aux techniques improvisées entraînées par ceux-ci. La forme et le numéro de pièce des outils spéciaux diffèrent selon les pays.

• Page 41
  Outil d’insertion de joint de fourche YM-01442 90890-01442 Cet outil est utilisé pour monter les bagues d’étanchéité de fourche. YU-3112-C, 90890-03112 Testeur de poche Yamaha YU-3112-C 90890-03112 Utiliser cet outil pour examiner la résistance de bobine, la tension de sortie et l’intensité. YU-8036-B…
• Page 42
  SPEZIALWERKZEUGE INFO SPEZIALWERKZEUGE Die folgenden Spezialwerkzeuge sind für korrekte und vollständige Einstell- und Montagearbeiten unerläßlich. Durch die Verwendung dieser Werkzeuge können Beschädigungen vermieden werden, die beim Gebrauch ungeeigneter Hilfsmittel oder improvisierter Techniken entstehen können. Bei der Bestellung von Spezialwerkzeug sollten die im folgenden aufgeführten Bezeichnungen und Teilenummern angegeben werden.
• Page 43
  YM-34487 Dynamischen Zündfunkenprüfer YM-34487 90890-06754 90890-06754 Zündungs-Prüfgerät Dieses Prüfgerät wird für die Kontrolle der Bauteile der Zündanlage benötigt. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA bond Nr. 1215 Dieses Dichmittel wird für die Paßflächen der Kurbel- gehäusehälften usw. verwendet.

• Page 44: Utensili Speciali

  UTENSILI SPECIALI INFO IC140002 UTENSILI SPECIALI Per una messa a punto e un montaggio completi e accurati sono necessari gli utensili speciali adeguati. L’uso dell’utensile speciale corretto contribuirà a evitare danni provocati dall’uso di utensili impropri o di tecniche improvvisate. La forma e il numero categorico usati per l’utensile speciale sono diversi a seconda del paese, quindi vengono forniti due tipi.

• Page 45
  90890-06754 Controllore dell’accensione Questo strumento è necessario per controllare i compo- nenti del sistema di accensione. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No. 1215 Questo sigillante (agglomerante) viene usato per la superficie di accoppiamento del carter, ecc..

• Page 46: Control Functions

  CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS EC151000 “ENGINE STOP” BUTTON The “ENGINE STOP” button 1 is located on the left handlebar. Continue pushing the “ENGINE STOP” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left handle- bar;…

• Page 47: Fonctions Des Commandes

  FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI INFO IC150000 FONCTIONS DES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI COMMANDES IC151000 BOUTON D’ARRET DE MOTEUR MOTORSTOPPKNOPF „ENGINE PULSANTE “ARRESTO “ENGINE STOP” STOP“ MOTORE” Il pulsante “ARRESTO MOTORE” 1 Ce bouton d’arrêt de moteur “ENGINE Dieser Motorstoppknopf „ENGINE…

• Page 48
  CONTROL FUNCTIONS INFO EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to acti- vate the front brake. EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine.

• Page 49: Funzioni Dei Comandi

  FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI INFO IC156000 LEVIER DE FREIN AVANT LEVA DI COMANDO DEL FRENO HANDBREMSHEBEL Le levier de frein avant 1 se trouve sur Der Handbremshebel 1 (Vorderrad- ANTERIORE le guidon droit. Le tirer vers le guidon La leva di comando del freno anteriore bremse) befindet sich am rechten 1 è…

• Page 50
  CONTROL FUNCTIONS INFO EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. 9 Never apply additional force to the side- stand. 9 Remove this sidestand before starting out. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose.
• Page 51
  FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI INFO IC15R001 BEQUILLE LATERALE ABNEHMBARER SEITENSTÄNDER CAVALLETTO STACCABILE Der Seitenständer 1 wird nur für das AMOVIBLE Questo cavalletto 1 viene usato per La béquille latérale 1 est utilisée pour Abstützen der Maschine während des supportare soltanto il veicolo quando è…

• Page 52: Fuel And Engine Mixing Oil

  FUEL AND ENGINE MIXING OIL INFO EC160051 FUEL AND ENGINE MIXING OIL Mix oil with the gas at the ratio specified below. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old.

• Page 53
  ESSENCE ET HUILE DE MELANGE DU MOTEUR KRAFTSTOFF UND MOTORGEMISCHÖL CARBURANTE E OLIO PER MISCELA PER MOTORI INFO IC160051 ESSENCE ET HUILE DE KRAFTSTOFF UND CARBURANTE E OLIO MELANGE DU MOTEUR MOTORGEMISCHÖL PER MISCELA PER MOTORI Mélanger le carburant à l’huile dans les Öl im nachfolgend angegebenen Ver- Miscelare l’olio con la benzina nel rap- proportions indiquées ci-dessous.

• Page 54: Starting And Break-In

  STARTING AND BREAK-IN INFO EC190000 STARTING AND BREAK-IN Before starting the machine, perform the checks in the pre-operation check list. Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time.

• Page 55: Mise En Marche Et Rodage

  MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN AVVIAMENTO E RODAGGIO INFO IC190000 MISE EN MARCHE ET STARTEN UND EINFAH- AVVIAMENTO E RODAGE RODAGGIO Avant la mise en marche, effectuez Prima di avviare il veicolo, eseguire i les vérifications indiquées dans la controlli della lista di controllo prima Vor dem Anfahren der Maschine, liste de contrôle avant utilisation.

• Page 56
  STARTING AND BREAK-IN INFO EC194001 BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows. Mixing oil: Mixing ratio: Yamalube “2-R” 15:1 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “ENGINE STOP”…

• Page 57: Starten Und Einfahren

  MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN AVVIAMENTO E RODAGGIO INFO IC194001 PROCEDURE DE RODAGE EINFAHRVORGÄNGE PROCEDURE DI RODAGGIO 1. Avant de lancer le moteur, rem- 1. Vor dem Starten des Motors, den 1. Prima di avviare il motore, riempi- Kraftstofftank für das Einfahren mit plissez le réservoir d’un mélange re il serbatorio del carburante con…

• Page 58
  STARTING AND BREAK-IN INFO 9 After the break-in or before each race, you must check the entire machine for loose fit- tings and fasteners as per “TORQUE- CHECK POINTS”. Tighten all such fasteners as required. 9 When any of the following parts have been replaced, they must be broken in.
• Page 59
  MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN AVVIAMENTO E RODAGGIO INFO 9 Après le rodage ou avant chaque 9 Dopo il rodaggio o prima di ciascu- 9 Nach dem Einfahren und vor course, il faut vérifier toutes les na gara, si deve controllare tutto il jedem Rennen müssen Sie gemäß…

• Page 60: Torque-Check Points

  TORQUE-CHECK POINTS INFO EC1A0013 TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering shaft to Steering shaft to frame handlebar Steering shaft to handle crown Handle crown to handlebar…

• Page 61: Points De Verification De Couple De Serrage

  POINTS DE VERIFICATION DE COUPLE DE SERRAGE INFO POINTS DE VERIFICATION DE COUPLE DE SERRAGE Construction du cadre Du cadre au cadre arrière Combinasion de siège Du réservoir à essence au cadre et de réservoir Montage du moteur Du cadre au moteur Du support du moteur au moteur Du support du moteur au cadre Direction…

• Page 62
  ANZUGSMOMENTE-PRÜFPUNKTE INFO ANZUGSMOMENTE-PRÜFPUNKTE Rahmenkonstruktion Rahmen und Hintere Rahmen Kombinierter Sitz und Tank Kraftstofftank am Rahmen Motoraufhängung Rahmen am Motor Motoraufhängung am Motor Motoraufhängung am Rahmen Lenkung Lenkerschaft Lenkerschaft am Rahmen an Lenkstange Lenkerschaft an Lenkerkrone Lenkerkrone an Lenkstange Radaufhängung Vorne Lenkerschaft an Vorderradgabel an Lenkerkrone Vorderradgabel…
• Page 63
  PUNTI DI CONTROLLO DELLA COPPIA INFO IC1A0013 PUNTI DI CONTROLLO DELLA COPPIA Costruzione del telaio Telaio-telaio posteriore Sella e serbatoio uniti Serbatoio del carburante-telaio Supporto del motore Telaio-motore Staffa motore-motore Staffa motore-telaio Sterzo Albero dello Albero dello sterzo-telaio sterzo-manubrio Albero dello sterzo-corona del manubrio Corona del manubrio-manubrio Sospensione Anteriore…

• Page 64: Cleaning And Storage

  CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall perfor- mance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.

• Page 65: Nettoyage Et Rangement

  NETTOYAGE ET RANGEMENT REINIGEN UND LAGERUNG PULITURA E IMMAGAZZINAMENTO INFO IC1B0000 NETTOYAGE ET REINIGEN UND PULITURA E IMMAGAZZI- RANGEMENT LAGERUNG NAMENTO NETTOYAGE REINIGEN IC1B1000 Un nettoyage fréquent de la machine Häufiges Reinigen Ihrer Maschine PULITURA stellt gefälliges Aussehen und ausge- réhausserra son aspect, maintiendra ses Una pulitura frequente del veicolo ne zeichnetes Leistungsvermögen sicher…

• Page 66
  CLEANING AND STORAGE INFO EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken avoid deterioration. After cleaning machine thoroughly, prepare it for storage as fol- lows: 1. Drain the fuel tank, fuel lines, and the carbu- retor float bowl.
• Page 67
  NETTOYAGE ET RANGEMENT REINIGEN UND LAGERUNG PULITURA E IMMAGAZZINAMENTO INFO IC1B2001 RANGEMENT IMMAGAZZINAMENTO LAGERUNG Si vous remisez votre machine pour 60 Se il veicolo deve essere immagazzina- Falls Ihre Maschine für länger als jours ou plus, vous devez prendre des to per 60 giorni o più, si devono pren- etwa 60 Tage gelagert werden soll, mesures de conservation pour éviter sa…

• Page 68: General Specifications

  SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: YZ250LC (EUROPE) YZ250R (USA) YZ250(R) (CDN, AUS, NZ, ZA) Model code number: 5UP1 (USA, CDN, ZA) 5UP2 (EUROPE) 5UP4 (AUS, NZ) Dimensions: USA, ZA AUS, NZ EUROPE ← ← Overall length 2,183 mm 2,182 mm (85.9 in)

• Page 69: Chassis

  SPEC GENERAL SPECIFICATIONS Carburetor: Type/Manufacturer PWK38S/KEIHIN Spark plug: Type/Manufacturer BR8EG/NGK (resistance type) 0.5~0.6 mm (0.020~0.024 in) Clutch type: Wet, multiple-disc Transmission: USA, ZA, AUS, NZ EUROPE, CDN ← Primary reduction system Gear ← Primary reduction ratio 63/21 (3.000) ← Secondary reduction system Chain drive Secondary reduction ratio 50/14 (3.571)

• Page 70: Maintenance Specifications

  SPEC MAINTENANCE SPECIFICATIONS EC212000 MAINTENANCE SPECIFICATIONS EC212100 ENGINE Item Standard Limit Cylinder head: USA, CDN, ZA, EUROPE AUS, NZ … Combustion chamber capacity 21.0 cm 21.5 cm (0.739 Imp oz, (0.757 Imp oz, 0.710 US oz) 0.727 US oz) … ……

• Page 71
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch housing thrust clearance 0.17~0.23 mm (0.007~0.009 in) … Clutch housing radial clearance 0.030~0.055 mm (0.001~0.002 in) … Clutch release method Inner push, cam push … Transmission: … Main axle deflection limit 0.01 mm (0.0004 in) ……
• Page 72
  SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M14 × 1.25 Spark plug M 8 × 1.25 Cylinder head (nut) M 8 × 1.25 (stud) M10 × 1.25 Cylinder (nut) M10 × 1.25 (stud) Power valve : M 5 ×…
• Page 73
  SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M10 × 1.25 Primary drive gear M20 × 1.0 Clutch boss M 6 × 1.0 Clutch spring M 5 × 0.8 Push lever axle M20 × 1.0 Drive sprocket M 6 ×…
• Page 74
  SPEC MAINTENANCE SPECIFICATIONS EC212201 CHASSIS Item Standard Limit Steering system: … Steering bearing type Taper roller bearing Front suspension: USA, CDN, ZA, EUROPE AUS, NZ … ← Front fork travel 300 mm (11.8 in) ← Fork spring free length 460 mm (18.1 in) 455 mm (17.9 in) ……
• Page 75
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Wheel: … Front wheel type Spoke wheel … Rear wheel type Spoke wheel … 21 × 1.60/Aluminum Front rim size/Material … 19 × 2.15/Aluminum Rear rim size/Material Rim runout limit: … Radial 2.0 mm (0.08 in) ……
• Page 76
  SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M 8 × 1.25 Handle crown and outer tube M 8 × 1.25 Under bracket and outer tube M24 × 1.0 Handle crown and steering shaft 14.5 M 8 ×…
• Page 77
  SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M 4 × 0.7 Rear brake master cylinder cap M10 × 1.25 Rear brake hose union bolt (caliper) M10 × 1.25 Rear brake hose union bolt (master cylinder) M20 ×…
• Page 78
  Ignition timing (B.T.D.C.) 0.18 mm (0.007 in) … Advancer type Electrical CDI: … Magneto-model (stator)/Manufacturer 5CU-02/YAMAHA … 720~1,080 Ω at 20°C (68°F) Source coil 1 resistance (color) (Black-Black/Red) … 44~66 Ω at 20°C (68°F) Source coil 2 resistance (color) (Green/Blue-Green/White) ……

• Page 79: General Torque Specifications

  GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard faste- ners with standard I.S.O. pitch threads. Torque specifications for special components or assem- blies are included in the applicable sections of this book. To avoid warpage, tighten multi-faste- ner assemblies in a crisscross fashion, in pro- gressive stages, until full torque is reached.

• Page 80: Caracteristiques Generales

  SPEC CARACTERISTIQUES GENERALES CARACTERISTIQUES CARACTERISTIQUES GENERALES Nom de modèle: YZ250LC (EUROPE) YZ250R (USA) YZ250(R) (CDN, AUS, NZ, ZA) Numéro de code de modèle: 5UP1 (USA, CDN, ZA) 5UP2 (EUROPE) 5UP4 (AUS, NZ) Dimensions: USA, ZA AUS, NZ EUROPE ← ← Longueur hors-tout 2.183 mm 2.182 mm…

• Page 81
  SPEC CARACTERISTIQUES GENERALES Carburateur: Type/fabricant PWK38S/KEIHIN Bougie: Type/fabricant BR8EG/NGK (type à résistance) Ecartement des électrodes 0,5~0,6 mm (0,020~0,024 in) Type d’embrayage: Humide, multi-disques Transmission: USA, ZA, AUS, NZ EUROPE, CDN ← Système de réduction primaire Engrenage ← Taux de réduction primaire 63/21 (3,000) Entraînement par chaîne ←…
• Page 82
  SPEC CARACTERISTIQUES D’ENTRETIEN CARACTERISTIQUES D’ENTRETIEN MOTEUR Article Standard Limite Culasse: USA, CDN, ZA, EUROPE AUS, NZ … Capacité de la chambre de combustion 21,0 cm 21,5 cm (0,793 Imp oz, (0,757 Imp oz, 0,710 US oz) 0,727 US oz) … ……
• Page 83
  SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite … Jeu de cloche d’embrayage pousser 0,17~0,23 mm (0,007~0,009 in) … Jeu radial de cloche d’embrayage 0,030~0,055 mm (0,001~0,002 in) … Méthode de débrayage Poussée interne, pousée par came Boîte de vitesses: … Limite de déformation d’arbre primaire 0,01 mm (0,0004 in) Limite de déformation d’arbre secondaire ……
• Page 84
  SPEC CARACTERISTIQUES D’ENTRETIEN Taille de Couple de serrage Pièce à serrer Q’té filetage m•kg ft•lb M14 × 1,25 Bougie M 8 × 1,25 Culasse (écrou) M 8 × 1,25 (goujon) M10 × 1,25 Cylinder (écrou) M10 × 1,25 (goujon) Clapet de puissance : M 5 ×…
• Page 85
  SPEC CARACTERISTIQUES D’ENTRETIEN Taille de Couple de serrage Pièce à serrer Q’té filetage m•kg ft•lb M10 × 1,25 Pignon primaire M20 × 1,0 Noix d’embrayage M 6 × 1,0 Ressort d’embrayage M 5 × 0,8 Axe de levier de poussé M20 ×…
• Page 86
  SPEC CARACTERISTIQUES D’ENTRETIEN PARTIE-CYCLE Article Standard Limite Direction: … Type de roulement de direction Roulement à rouleaux conique Suspention avant: USA, CDN, ZA, EUROPE AUS, NZ … 300 mm (11,8 in) ← Débattement de fourche avant 460 mm (18,1 in) ← Longueur libre de ressort de fourche 455 mm (17,9 in) ……
• Page 87
  SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Roue: … Type de roue avant Roue à rayons … Type de roue arrière Roue à rayons … 21 × 1,60/Aluminum Taille/matériau de jante avant … 19 × 2,15/Aluminum Taille/matériau de jante arrière Limite de voile de jante: ……
• Page 88
  SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Q’té filetage m•kg ft•lb M 8 × 1,25 Couronne de guidon et tube externe M 8 × 1,25 Etrier inférieur et tube externe M24 × 1,0 Couronne de guidon et colonne de direction 14,5 M 8 ×…
• Page 89
  SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Q’té filetage m•kg ft•lb M 4 × 0,7 Coupelle de maître-cylindre de frein arrière M10 × 1,25 Boulon d’union de tuyau de frein arrière (ètrier) M10 × 1,25 Boulon d’union de tuyau de frein arrière (maître-cylindre) M20 ×…
• Page 90
  Avance d’allumage (AV. PMH) 0,18 mm (0,007 in) … Type de dispositif d’avance Electrique CDI: … Magnéto-modèle (stator)/Fabricant 5CU-02/YAMAHA … 720~1,080 Ω à 20°C (68°F) Résistance de bobinage de source 1 (couleur) (noir-noir/rouge) 44~66 Ω à 20°C (68°F) … Résistance de bobinage de source 2…

• Page 91: Definition Des Unites

  SPECIFICATIONS GENERALES DE COUPLE/ SPEC DEFINITION DES UNITES SPECIFICATIONS GENERALES DE COUPLE Ce tableau spécifie les couples de serrage des attaches standard avec filetage à pas I.S.O. stan- dard. Les spécifications de couple pour les compo- sants ou ensembles spéciaux sont indiquées das les sections appropriées de ce manuel.

• Page 92: Technische Daten

  SPEC ALLGEMEINE TECHNISCHE DATEN TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN Modellname: YZ250LC (EUROPA) YZ250R (USA) YZ250(R) (CDN, AUS, NZ, ZA) Modell-Code-Nummer: 5UP1 (USA, CDN, ZA) 5UP2 (EUROPA) 5UP4 (AUS, NZ) Abmessungen: USA, ZA AUS, NZ EUROPA ← ← Gesamtlänge 2.183 mm 2.182 mm (85,9 in) (85,9 in)

• Page 93: Allgemeine Technische Daten

  SPEC ALLGEMEINE TECHNISCHE DATEN Vergaser: Modell/Hersteller PWK38S/KEIHIN Zündkerze: Modell/Hersteller BR8EG/NGK (Widerstand, Typ) Elektrodenabstand 0,5~0,6 mm (0,020~0,024 in) Kupplungsbauart: Mehrscheiben-Naßkupplung Getriebe: USA, ZA, AUS, NZ EUROPA, CDN ← Primäruntersetzungssystem Zahnrad ← Primäruntersetzungsverhältnis 63/21 (3,000) ← Sekundäruntersetzungssystem Kettenantrieb Sekundäruntersetzungsverhältnis 50/14 (3,571) 49/14 (3,500) ←…

• Page 94
  SPEC WARTUNGSDATEN WARTUNGSDATEN MOTOR Bauteil Standard Grenze Zylinderkopf: USA, CDN, ZA, EUROPA AUS, NZ … Brennkammerkapazität 21,0 cm 21,5 cm (0,739 Imp oz, (0,757 Imp oz, 0,710 US oz) 0,727 US oz) … … Verzugsgrenze 0,03 mm (0,0012 in) Zylinder: Bohrungsdurchmesser 66,400~66,414 mm 66,5 mm (2,618 in)
• Page 95
  SPEC WARTUNGSDATEN Bauteil Standard Grenze Kupplungsgehäuse: Axialspiel 0,17~0,23 mm (0,007~0,009 in) … Kupplungsgehäuse: Radialspiel 0,030~0,055 mm … (0,001~0,002 in) Kupplungsausrückmechanismus Innendruck, Nockendruck … Getriebe: … Schlaggrenze der Haptwelle 0,01 mm (0,0004 in) … Schlaggrenze der Antriebswelle 0,01 mm (0,0004 in) Schaltung: ……
• Page 96
  SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M14 × 1,25 Zündkerze M 8 × 1,25 Zylinderkopf (Mutter) M 8 × 1,25 (Stehbolzen) M10 × 1,25 Zylinder (Mutter) M10 × 1,25 (Stehbolzen) Leistungsventil: M 5 × 0,8 Halter M 5 × 0,8 Pleuelstange M 5 ×…
• Page 97
  SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M10 × 1,25 Primärantriebszahnrad M20 × 1,0 Kupplungsnabe M 6 × 1,0 Kupplungsfeder M 5 × 0,8 Schubhebelachse M20 × 1,0 Antriebskettenrad M 6 × 1,0 Schaltführung M 6 × 1,0 Anschlaghebel M 8 ×…
• Page 98
  SPEC WARTUNGSDATEN FAHRGESTELL Bauteil Standard Grenze Lenkungssystem: … Lenkerschaftlager Kegelrollenlager Vorderradaufhängung: USA, CDN, ZA, EUROPA AUS, NZ … ← Hub der Vorderradgabel 300 mm (11,8 in) ← Ungespannte Federlänge 460 mm (18,1 in) 455 mm (17,9 in) … Federkonstante STD K=4,22 N/mm K=ca.
• Page 99
  SPEC WARTUNGSDATEN Bauteil Standard Grenze Räder: … Bauart: Vorderrad Speichenräder … Hinterrad Speichenräder … 21 × 1,60/Aluminum Felgengröße: Vorderrad/Baustoff … 19 × 2,15/Aluminum Hinterrad/Baustoff Zuläßiger Felgenschlag: … Senkrecht 2,0 mm (0,08 in) … Seitlich 2,0 mm (0,08 in) Antriebskette: … Bauart/Hersteller DID520DMA2 SDH/DAIDO ……
• Page 100
  SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M 8 × 1,25 Lenkerkrone und äußere Rohr M 8 × 1,25 Untere Gabelbrücke und äußere Rohr M24 × 1,0 Lenkerkrone und Lenkerschaft 14,5 M 8 × 1,25 Lenkerhalter (obere) M28 × 1,0 Lenkerringmutter Siehe ANMERKUNG.
• Page 101
  SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M 6 × 1,0 Hinterrad-Hauptbremszylinder und Rahmen M 4 × 0,7 Hintrerred-Hauptbremszylinder kappe M10 × 1,25 Hinterrad-Bremsschlauch- Verbindungsschraube (bremssattel) M10 × 1,25 Hinterrad-Bremsschlauch- Verbindungsschraube (Hauptbremszylinder) M20 × 1,5 Hinterradachse und Mutter 12,5 M 8 ×…
• Page 102
  0,18 mm (0,007 in) (Vor dem oberen Totpunkt) … Zündversteller Elektrisch-Ausführung CDI: … Modell (staor)/Hersteller 5CU-02/YAMAHA … 720~1.080 Ω bei 20°C (68°F) Widerstand der Stromspule 1 (Farbe) (Schwarz-Schwarz/Rot) … 44~66 Ω bei 20°C (68°F) Widerstand der Stromspule 2 (Farbe) (Grün/Blau-Grün/Waiß) ……

• Page 103: Allgemeine Anzugsdaten

  ALLGEMEINE ANZUGSDATEN/ SPEC DEFINITION DER EINHEITEN ALLGEMEINE ANZUGSDATEN Diese Tabelle spezifiziert Anzugsmomente für normale Befestigungselemente mit normalen I.S.O. Gewindenormen. Anzugsmomente für besondere Bauteile bzw. Bauteileinheiten sind in den einzelnen Abschnitten in dieser Wartungs- anleitung aufgefügrt. Wenn Teile mit mehreren Befestigungselementen festgezogen werden, die Schrauben und Muttern kreuzweise und in…

• Page 104: Specifiche Generali

  SPEC SPECIFICHE GENERALI IC200000 SPECIFICHE IC211000 SPECIFICHE GENERALI Nome del modello: YZ250LC (EUROPA) YZ250R (USA) YZ250(R) (CDN, AUS, NZ, ZA) Numero di codice del modello: 5UP1 (USA, CDN, ZA) 5UP2 (EUROPA) 5UP4 (AUS, NZ) Dimensioni: USA, ZA AUS, NZ EUROPA CDN, ←…

• Page 105
  SPEC SPECIFICHE GENERALI Carburatore: Tipo/Costruttore PWK38S/KEIHIN Candela: Tipo/Costruttore BR8EG/NGK (tipo di resistenza) Distanza tra gli elettrodi 0,5~0,6 mm (0,020~0,024 in) Tipo di frizione: Bagnata, a più dischi Trasmissione: USA, ZA, AUS, NZ EUROPA, CDN ← Sistema di riduzione primario Ingranaggio ←…

• Page 106: Specifiche Di Manutenzione

  SPEC SPECIFICHE DI MANUTENZIONE IC212000 SPECIFICHE DI MANUTENZIONE IC212100 MOTORE Voce Valore normale Limite Testa cilindro: USA, CDN, ZA, EUROPA AUS, NZ … Capacità della camera di combustione 21,0 cm 21,5 cm (0,739 Imp oz, (0,757 Imp oz, 0,710 US oz) 0,727 US oz) ……

• Page 107
  SPEC SPECIFICHE DI MANUTENZIONE Voce Valore normale Limite … Gioco di spinta del coperchio della frizione 0,17~0,23 mm (0,007~0,009 in) … Gioco radiale del coperchio della frizione 0,030~0,055 mm (0,001~0,002 in) … Metodo di distacco della frizione Spinta interna, spinta camma Trasmissione: ……
• Page 108
  SPEC SPECIFICHE DI MANUTENZIONE Dimensioni della Coppia di serraggio Parte da serrare Quantità filettatura m•kg ft•lb M14 × 1,25 Candela M 8 × 1,25 Testa cilindro (dado) M 8 × 1,25 (Prigioniero) M10 × 1,25 Cilindro (dado) M10 × 1,25 (prigioniero) Valvola di potenza: M 5 ×…
• Page 109
  SPEC SPECIFICHE DI MANUTENZIONE Dimensioni della Coppia di serraggio Parte da serrare Quantità filettatura m•kg ft•lb M10 × 1,25 Ingranaggio conduttore primario M20 × 1,0 Mozzo della frizione M 6 × 1,0 Molla della frizione M 5 × 0,8 Asse della leva di spinta M20 ×…
• Page 110
  SPEC SPECIFICHE DI MANUTENZIONE IC212201 TELAIO Voce Valore normale Limite Sistema dello sterzo: … Tipo di cuscinetto dello sterzo Cuscinetto a sfere conico Sospensione anteriore: USA, CDN, ZA, EUROPA AUS, NZ … 300 mm (11,8 in) ← Corsa della forcella anteriore Lunghezza libera della molla della forcella 460 mm (18,1 in) ←…
• Page 111
  SPEC SPECIFICHE DI MANUTENZIONE Voce Valore normale Limite Ruota: … Tipo di ruota anteriore Ruota a razze … Tipo di ruota poster Ruota a razze … 21 × 1,60/Alluminio Dimensioni/Materiale del cerchione anteriore … Dimensioni/Materiale del cerchione posteriore 19 × 2,15/Alluminio Limite di scentratura del cerchione: ……
• Page 112
  SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni della Quantità Parte da serrare filettatura m•kg ft•lb M 8 × 1,25 Corona del manubrio e tubo esterno M 8 × 1,25 Staffa inferiore e tubo esterno M24 × 1,0 Corona del manubrio e albero dello sterzo 14,5 M 8 ×…
• Page 113
  SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni della Quantità Parte da serrare filettatura m•kg ft•lb M10 × 1,25 Bullone di unione del tubo flessibile del freno posteriore (pinza) M10 × 1,25 Bullone di unione del tubo flessibile del freno posteriore (cilindro principale) M20 ×…
• Page 114
  Messa in fase dell’accensione (B.T.D.C.) 0,18 mm (0,007 in) … Tipo di anticipatore Elettrico CDI: … Modello (statore)/Costruttore del magnete 5CU-02/YAMAHA 720~1.080 Ω à 20°C (68°F) … Resistenza 1 della bobina di origine (colore) (Nero-Nero/Rosso) … 44~66 Ω à 20°C (68°F)

• Page 115: Definizione Delle Unit

  SPECIFICHE GENERALI RELATIVE ALLA COPPIA/ SPEC DEFINIZIONE DELLE UNITÀ IC220001 SPECIFICHE GENERALI RELATIVE ALLA COPPIA Questa tabella specifica la coppia per i dispositivi di fissaggio standard con filettature a passo I.S.O. standard. Le specifiche relative alla coppia per componenti o gruppi speciali sono incluse nelle sezioni pertinenti di questo manuale.

• Page 116: Cable Routing Diagram

  SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM A Pass the fuel tank breather hose G Pass the air vent hoses, overflow 1 Fuel tank breather hose 2 Cable guide between the handlebar and ten- hose and transmission oil 3 Throttle cable sion bar, then insert its end into breather hose between the frame 4 Clamp…

• Page 117: Schema De Cheminement Des Cables

  SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI IC240000 SCHEMA DE DIAGRAMMA DEL KABELFÜHRUNGSÜBER- CHEMINEMENT DES SICHTPLAN PASSAGGIO DEI CAVI 1 Kraftstofftank — Belüftungsschlauch 1 Sfiato del serbatoio del carburante CABLES 2 Kabelführung 2 Guida per cavi 1 Tuyau de reniflard de réservoir à…

• Page 118
  SPEC CABLE ROUTING DIAGRAM B Clamp the “ENGINE STOP” but- E Clamp the radiator breather 1 Ground lead 2 Ignition coil lead ton lead, ground lead, ignition hose and CDI magneto lead at 3 Clamp coil lead, wireharness and CDI the rear of the down-tube with 4 Wireharness magneto lead with the clamp…
• Page 119
  SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Conduttore di terra 1 Fil de masse 1 Massekabel 2 Zündspulekabel 2 Conduttore de la bobina di accencsione 2 Fil de bobine d’allumage 3 Klemme 3 Brida 3 Bride 4 kalbelbaum 4 Complesso conduttori…
• Page 120
  SPEC CABLE ROUTING DIAGRAM A Pass the clutch cable into the F Fasten the ground lead together 1 Clutch cable 2 Cable guide cable guide. with the front installation portion B Clamp the clutch cable, high 3 Ground lead of the ingnition coil. G Pass the radiator breather hose 4 Clamp tension cord and wireharness at…
• Page 121
  SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Câble d’embrayage 1 Kupplungskabel 1 Cavo della frizione 2 Kabelführung 2 Guide de câble 2 Guida per cavi 3 Massekabel 3 Fil de masse 3 Conduttore di terra 4 Klemme 4 Bride 4 Brida…
• Page 122
  SPEC CABLE ROUTING DIAGRAM A Install the brake hose so that its pipe portion 1 Master cylinder 2 Brake hose holder directs as shown and lightly touches the projec- 3 Brake hose tion on the caliper. B Pass the brake hose into the brake hose holders.
• Page 123
  SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Maître-cylindre 1 Hauptbremszylinder 1 Cilindro principale 2 Support de tuyau de frein 2 Bremsschlauchhalter 2 Supporto del tubo flessibile del freno 3 Tuyau de frein 3 Bremsschlauch 3 Tubo flessibile del freno A Bremsschlauch å…
• Page 124
  SPEC CABLE ROUTING DIAGRAM A Install the brake hose so that its pipe portion 1 Brake hose 2 Master cylinder directs as shown and lightly touches the 3 “ENGINE STOP” button lead projection on the master cylinder. B Pass the “ENGINE STOP” button lead in 4 “ENGINE STOP”…
• Page 125
  SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Tuyau de frein 1 Bremsschlauch 1 Tubo flessibile del freno 2 Maître-cylindre 2 Hauptbremszylinder 2 Cilindro principale 3 Fil de bouton d’arrêt du moteur “ENGI- 3 Leitungskabel des Motorstoppknopfes 3 Conduttore del pulsante “ARRESTO NE STOP”…

• Page 126: Maintenance Intervals

  If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. After…

• Page 127
  Replace bearing TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE, CONTROL CABLE Yamaha cable lube or Check routing and connection SAE 10W-30 motor oil Lubricate…
• Page 128
  INSP MEMO…
• Page 129
  En cas de doute au sujet des inter- valles d’entretien et de lubrification à adopter, consultez votre concessionnaire Yamaha. Chaque Chaque Après Chaque…
• Page 130
  INSP PROGRAMME D’ENTRETIEN Chaque Chaque Après Chaque Partie trois- cinquiè- nécessa- Remarques rodage course ième BOUGIE Contrôler et nettoyer Changer CHAINE DE TRANSMISSION Utiliser du lubrifiant Graisser, jeu, alignement pour chaîne Changer Jeu de la chaîne: 40~50 mm (1,6~2,0 in) CIRCUIT DE REFROIDISSEMENT Contrôler le niveau du liquide…
• Page 131
  Resserrer les boulons de la roue dentée Contrôler les roulements Changer les roulements Graisser Graisse à base de lithium ACCELERATEUR, CABLES DE COMMANDE Yamaha lube pour câble ou Contrôler le chaminement et le Huile moteur SAE 10W-30 branchement Graisser…
• Page 132
  Wetterbedingungen, dem Terrain, der geographischen Lage und den individuellen Fahrgewohnhei- ten sind die aufgeführten Wartungs- und Schmierintervalle zu ändern. Falls Fragen hinsichtlich der War- tungs- und Schmierintervalle auftreten sollten, wenden Sie sich bitte an Ihren Yamaha Fachhändler. Nach…
• Page 133
  INSP WARTUNGSINTERVALLE Nach Nach Nach Nach dem jedem jedem Benennung jedem Bemerunen Einfahren dritten fünften Erforderlich Rennen Rennen Rennen KÜHLANLAGE Kühlmittelstand prüfen und auf Undichtigkeit achten Funktion des Kühlerdeckels kontrollieren Kühlmittel wechseln Alle zwie Jahre Schläuche prüfen MUTTERN UND SCHRAUBEN Siehe Abschnitt AN DER AUSSENSEITE „STARTEN UND…
• Page 134
  Bemerunen Einfahren dritten fünften Erforderlich Rennen Rennen Rennen RÄDER, REIFEN Reifendruck, Felgenschlag, Reifenverschleiß und Speichen auf Lockerung prüfen Ketternrad-Befestigungsschraube nachziehen Lager prüfen Lager erneuern Schmieren Lithium-Fett GASDREHGRIFF, GASSEIL Yamaha Seilzug- Seilzugführung und Anschlüsse Schmiermittel oder prüfen Motoröl SAE 10W-30 Schmieren…

• Page 135: Intervalli Di Manutenzione

  Se si hanno dubbi sugli interval- li da seguire per la manutenzione e la lubrificazione del veicolo, consultare il concessionario Yamaha. In base…

• Page 136
  INSP INTERVALLI DI MANUTENZIONE In base Dopo il Ogni Ogni Voce Ogni alle Osservazioni rodaggio gara cinque necessità IMPIANTO DI RAFFREDDAMENTO Controllo livello e perdite di liquido refrigerante Controllo funzionamento del tappo del radiatore Sostituzione del liquido refrigerante Ogni due anni Ispezione dei tubi flessibili DADI E VITI ESTERNI Consultare la sezione…
• Page 137
  Riserraggio bullone del rocchetto Ispezione dei cuscinetti Sostituzione dei cuscinetti Lubrificazione Grasso a base di litio VALVOLA A FARFALLA, CAVO DI COMANDO Lubrificante per cavi Controllo dell’instradamento e del Yamaha oppure olio per collegamento motori SAE 10W-30 Lubrificazione…

• Page 138: Pre-Operation Inspection And Maintenance

  INSP PRE-OPERATION INSPECTION AND MAINTENANCE EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. EC321000 GENERAL INSPECTION AND MAINTENANCE Item Routine Page…

• Page 139
  INSP INSPECTION ET ENTRETIEN AVANT UTILISATION INSPECTION ET ENTRETIEN AVANT UTILISATION Avant la conduite pour le rodage, l’entraînement ou une course, s’assurer que la machine est en bou état de marche. Avant d’utiliser cette machine, contrôler les points suivants: INSPECTION GENERALE ET ENTRETIEN Partie Routine Page…
• Page 140
  INSP PRÜFUNG UND WARTUNG VOR DER INBETRIEBNAHME PRÜFUNG UND WARTUNG VOR DER INBETRIEBNAHME Vor dem Einfahren, einer Übungs-oder Rennfahrt, immer die Maschine auf guten Betriebszustand kontrollieren. Vor der Benutzung dieser Maschine sind die folgenden Punkte zu prüfen: ALLGEMEINE PRÜFUNG UND WARTUNG Benennung Vorgang Seite…
• Page 141
  INSP ISPEZIONE E MANUTENZIONE PRIMA DEL FUNZIONAMENTO IC320000 ISPEZIONE E MANUTENZIONE PRIMA DEL FUNZIONAMENTO Prima di usarlo per il rodaggio, per allenamento o per una gara, accertarsi che il veicolo sia in buone condi- zioni di funzionamento. Prima di usare questo veicolo, controllare i punti che seguono. IC321000 ISPEZIONE E MANUTENZIONE GENERALI Voce…
• Page 142
  ENGINE/COOLANT LEVEL INSPECTION/ INSP COOLANT REPLACEMENT EC350000 ENGINE EC351011 COOLANT LEVEL INSPECTION Do not remove the radiator cap 1 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 143
  MOTEUR/VERIFICATION DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT/CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT MOTOR/INSPEKTION DES KÜHLMITTELSTANDES/ERNEUERUNG DES KÜHLMITTELS INSP MOTORE/ISPEZIONE DEL LIVELLO DEL LIQUIDO REFRIGERANTE/ SOSTITUZIONE DEL LIQUIDO REFRIGERANTE IC350000 MOTEUR MOTOR MOTORE IC351011 VERIFICATION DU NIVEAU DU INSPEKTION DES ISPEZIONE DEL LIVELLO DEL LIQUIDE DE REFROIDISSEMENT KÜHLMITTELSTANDES LIQUIDO REFRIGERANTE…
• Page 144
  INSP COOLANT REPLACEMENT Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: 9 Coolant drain bolt 1 3. Remove: 9 Radiator cap Drain the coolant completely.
• Page 145
  CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP ERNEUERUNG DES KÜHLMITTELS SOSTITUZIONE DEL LIQUIDO REFRIGERANTE Fare attenzione che il liquido refrige- Prendre garde à ne pas verser de Darauf achten, daß kein Kühlmittel rante non schizzi sulle superfici ver- liquide de refroidissement sur les lackierte Flächen verspritzt…
• Page 146
  INSP RADIATOR CAP INSPECTION 9 Do not mix more than one type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. 9 Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be handled with special care.
• Page 147
  VERIFICATION DU BOUCHON DU RADIATEUR INSP INSPEKTION DES KÜHLERDECKELS ISPEZIONE DEL TAPPO DEL RADIATORE 9 Ne pas mélanger plusieurs solutions 9 Non miscelare più di un tipo di anti- 9 Niemals Äthylenglykol-Frost- antigel au glycol d’éthyle contenant gelo a base di glicole etilenico conte- schutzmittel Korrosions- des produits anticorrosion pour…
• Page 148
  RADIATOR CAP OPENING PRESSURE INSPECTION/ INSP COOLING SYSTEM INSPECTION EC356002 RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: 9 Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Adapter: YU-33984/90890-01352 NOTE: Apply water on the radiator cap seal. 3 Radiator cap 2.
• Page 149
  VERIFICATION DE LA PRESSION D’OUVERTURE DU BOUCHON DU RADIATEUR/VERIFICATION DE SYSTEME DE REFROIDISSEMENT INSPEKTION DES KÜHLERDECKELÖFFNUNGSDRUCKS/INSPEKTION DES KÜHLSYSTEMS INSP ISPEZIONE DELLA PRESSIONE DI APERTURA DEL TAPPO DEL RADIATORE/ ISPEZIONE DELL’IMPIANTO DI RAFFREDDAMENTO IC356002 VERIFICATION DE LA PRESSION INSPEKTION KÜHLER- ISPEZIONE DELLA PRESSIONE D’OUVERTURE DU BOUCHON DECKELÖFFNUNGSDRUCKS DI APERTURA DEL TAPPO DEL…
• Page 150
  INSP CLUTCH ADJUSTMENT NOTE: 9 Do not apply pressure more than specified pressure. 9 Radiator should be filled fully. 4. Inspect: 9 Pressure Impossible to maintain the specified pres- sure for 10 seconds¡Repair. 9 Radiator 1 9 Radiator hose joint 2 Coolant leakage¡Repair or replace.
• Page 151
  REGLAGE DE L’EMBRAYAGE INSP EINSTELLUNG DER KUPPLUNG REGOLAZIONE DELLA FRIZIONE HINWEIS: N.B.: NOTA: 9 Ne pas appliquer de pression supé- 9 Non applicare pressione superiore alla 9 Den spezifizierten Druck nicht Über- rieure à la pression spécifiée. pressione specificata. schreiten. 9 Le radiateur doit être entièrement 9 Il radiatore dovrebbe essere completa- 9 Der Kühler sollte vollständig gefüllt…
• Page 152
  THROTTLE CABLE ADJUSTMENT/ INSP THROTTLE LUBRICATION EC35A001 THROTTLE CABLE ADJUSTMENT 1. Check: 9 Throttle grip free play a Out of specification¡Adjust. Throttle grip free play ? a : 3~5 mm (0.12~0.20 in) 2. Adjust: 9 Throttle grip free play Throttle grip free play adjustment steps: 9 Loosen the locknut 1.
• Page 153
  REGLAGE DU CABLE D’ACCELERATION/GRAISSAGE DE L’ACCÉLÉRATEUR EINSTELLUNG DES GASSEILES/SCHMIERUNG DES GASSEILS INSP REGOLAZIONE DEL CAVO DELL’ACCELERATORE/ LUBRIFICAZIONE DELLA VALVOLA A FARFALLA IC35A001 REGLAGE DU CABLE EINSTELLUNG DES GASSEILES REGOLAZIONE CAVO D’ACCELERATION 1. Kontrollieren: DELL’ACCELERATORE 9 Spiel am Gasdrehgriff a 1. Contrôler: 1.
• Page 154
  INSP AIR FILTER CLEANING 3. Install: 9 Throttle cable cap 1 Nm (0.1 m•kg, 0.7 ft•lb) 9 Cap cover EC35G041 AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and dam- age. Never run the engine without the air filter element in place;…
• Page 155
  NETTOYAGE DU FILTRE A AIR INSP REINIGUNG DES LUFTFILTERS PULITURA DEL FILTRO DELL’ARIA 3. Monter: 3. Installare: 3. Einbauen: 9 Capuchon du câble d’accéléra- 9 Calotta del cavo dell’accelerato- 9 Gasseilkappe teur 1 Nm (0,1 m•kg, 0,7 ft•lb) 1 Nm (0,1 m•kg, 0,7 ft•lb) 1 Nm (0,1 m•kg, 0,7 ft•lb) 9 Kappenabdeckung 9 Couvercle de capuchon…
• Page 156
  INSP TRANSMISSION OIL LEVEL CHECK 3. Inspect: 9 Air filter element Damage¡Replace. 4. Apply: 9 Foam-air-filter oil or equivalent oil To the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping. 5. Install: 9 Filter guide 1 NOTE: Align the projection a on filter guide with the hole b in air filter element.
• Page 157
  CONTROLE DU NIVEAU DE L’HUILE DE BOITE DE VITESSES INSP PRÜFUNG DES GETRIEBEÖLSTANDES CONTROLLO DEL LIVELLO DELL’OLIO DELLA TRASMISSIONE 3. Examiner: 3. Ispezionare 3. Prüfen: 9 Elément du filtre à air 9 Elemento del filtro dell’aria 9 Luftfilterelement Danni ¡ Sostituirlo. Endommagement¡Changer.
• Page 158
  INSP TRANSMISSION OIL REPLACEMENT 3. Check: 9 Transmission oil level Transmission oil level checking steps: 9 Remove the oil check bolt 1. 9 Inspect the oil level. NOTE: Be sure the machine is positioned straight up when inspecting the oil level. Never attempt to remove the oil check bolt just after high speed operation.
• Page 159
  CHANGEMENT DE L’HUILE DE BOITE DE VITESSES INSP ERNEUERUNG DES GETRIEBEÖLS SOSTITUZIONE DELL’OLIO DELLA TRASMISSIONE 3. Contrôler: 3. Controllare: 3. Kontrollieren: 9 Niveau d’huile de boîte de 9 Livello dell’olio della trasmis- 9 Getriebeölstand vitesses sione Prüfschritte des Getriebeölstan- Passi del controllo del livello Procédure de contrôle de niveau des: dell’olio della trasmissione:…
• Page 160
  INSP PILOT AIR SCREW ADJUSTMENT 4. Remove: 9 Oil drain bolt 1 9 Oil filler cap 2 Drain the transmission oil. 5. Install: 9 Aluminum washer 9 Oil drain bolt 1 20 Nm (2.0 m•kg, 14 ft•lb) 6. Fill: 9 Transmission oil Recommended oil: Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil…
• Page 161
  REGLAGE DE LAVIS DE RICHESSE INSP EINSTELLUNG DER LEERLAUFTREGULIERSCHRAUBE REGOLAZIONE DELLA VITE DELL’ARIA PILOTA 4. Déposer: 4. Togliere: 4. Ausbauen: 9 Boulon de vidange d’huile 1 9 Bullone di scarico dell’olio 1 9 Ölablaßschraube 1 9 Bouchon de remplissage d’huile 9 Tappo di riempimento dell’olio 9 Öleinfüllschraube 2 Das Getriebeöl ablassen.
• Page 162
  INSP IDLE SPEED ADJUSTMENT/MUFFLER INSPECTION/ SILENCER FIBER REPLACEMENT EC35M001 IDLE SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Adjust: 9 Idle speed Adjustment steps: Turn the throttle stop screw 1 until the engine runs at the lowest possible speed. To increase idle speed ¡…
• Page 163
  REGLAGE DU REGIME DE RALENTI/CONTROLE DU SILENCIEUX D’ECHAPPMENT/CHANGEMENT DE FIBRE DU SILENCIEUX EINSTELLUNG DER LEERLAUFDREHZAHL/INSPEKTION DES INSP SCHALLDÄMPFERS/ERNEUERUNG DES SCHALLDÄMPFERFASEREINSATZES REGOLAZIONE DEL NUMERO DI GIRI AL MINIMO/ISPEZIONE DELLA MARMITTA/ SOSTITUZIONE DELLA FIBRA DEL SILENZIATORE IC35M001 REGLAGE REGIME EINSTELLUNG LEERLAUF- REGOLAZIONE DEL NUMERO DI RALENTI DREHZAHL GIRI AL MINIMO…

• Page 164: Silencer Fiber Replacement

  Fully apply Quick gasket ® (Yamaha bond No. 1215) or equivalent as shown. Quick gasket ® ACC-QUICK-GS-KT Yamaha bond No. 1215: 90890-85505 5. Install: 9 Bolt (fiber) 1 10 Nm (1.0 m•kg, 7.2 ft•lb) 9 Silencer 2 9 Bolt [silencer (front)] 3 12 Nm (1.2 m•kg, 8.7 ft•lb)

• Page 165
  (Yamaha bond Nr. Applicare ovunque Quick Gasket ® ® d’étanchéité Quick Gasket ® (Yamaha 1215) oder gleichwertiges Produkt voll (Yamaha Bond n° 1215) o equivalente, Bond n° 1215) ou équivalent comme auftragen, wie dargestellt. come illustrato. illustré. Quick Gasket ® Quick Gasket ®…
• Page 166
  INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING Bleed the brake system if: 9 The system has been disassembled. 9 A brake hose has been loosened or removed. 9 The brake fluid is very low. 9 The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bleed.

• Page 167: Partie Cycle

  PARTIE CYCLE/PURGE DE L’AIR DU SYSTEME DE FREINAGE INSP FAHRGESTELL/ENTLÜFTUNG DER BREMSANLAGE TELAIO/ SPURGO DELL’ARIA DALL’IMPIANTO FRENANTE IC360000 PARTIE CYCLE FAHRGESTELL TELAIO PURGE DE L’AIR DU SYSTEME ENTLÜFTUNG DER BREMSANLAGE IC361012 DE FREINAGE SPURGO DELL’ARIA DALL’IMPIAN- TO FRENANTE Die Bremsanlage muß unbedingt in den folgenden Fallen entlüftet werden: Purger le système de freinage si: 9 Nach Demontage und Wiederzu-…

• Page 168
  INSP FRONT BRAKE ADJUSTMENT NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. j. Add brake fluid to the level line on the reservoir.
• Page 169
  REGLAGE DE FREIN AVANT INSP EINSTELLUNG DER VORDERRADBREMSE REGOLAZIONE DEL FRENO ANTERIORE HINWEIS: N.B.: NOTA: Si la purge est difficile, il peut être Se lo spurgo risulta difficoltoso, Falls das Entlüften schwierig ist, nécessaire de laisser le système du può essere necessario lasciare stabi- dann muß…

• Page 170: Rear Brake Adjustment

  REAR BRAKE ADJUSTMENT/ INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364004 REAR BRAKE ADJUSTMENT 1. Check: 9 Brake pedal height a Out of specification¡Adjust. Brake pedal height a a : Zero mm (Zero in) NOTE: The brake pedal height is the vertical distance from the inside top end of the footrest.

• Page 171
  REGLAGE DU FREIN ARRIERE/ VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN AVANT EINSTELLUNG DER HINTERRADBREMSE/ INSP INSPEKTION UND ERNEUERUNG DER VORDERRAD-BREMSBELAGPLATTE REGOLAZIONE DEL FRENO POSTERIORE/ ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE IC364004 REGLAGE DU FREIN ARRIERE EINSTELLUNG DER HINTERRAD- REGOLAZIONE FRENO 1.
• Page 172
  INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT 9 Loosen the pad pin 2. 9 Remove the brake hose holder 3 and caliper 4 from the front fork. 9 Remove the pad pin and brake pads 5. 9 Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end.
• Page 173
  VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN AVANT INSP INSPEKTION UND ERNEUERUNG DES VORDERRAD-BREMSBELAGPLATTE ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE 9 Desserrer la goupille de plaquette 9 Allentare la spina della pastiglia 9 Bremsbelagstift 2 lösen. 9 Bremsleitungshalter 9 Déposer le support du tuyau de 9 Togliere il supporto del tubo fles- Bremsbelag 4 von der Vorderrad-…

• Page 174: Front Wheel And Rear Wheel

  INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT 9 Install the pad pin plug w. Pad pin plug: 3 Nm (0.3 m•kg, 2.2 ft•lb) 3. Inspect: 9 Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: 9 Brake lever operation A softy or spongy feeling ¡…

• Page 175
  VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN ARRIERE INSP INSPEKTION UND ERNEUERUNG DES HINTERRAD-BREMSBELAGPLATTE ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE 9 Installare il tappo della spina della 9 Bremsbelagplattenstifte w 9 Installer le bouchon de goupille anbrin- pastiglia w.
• Page 176
  INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT 9 Remove the pad pin 6 and brake pads 7. 9 Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. 9 Loosen the bleed screw and push the caliper piston in.
• Page 177
  VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN ARRIERE INSP INSPEKTION UND ERNEUERUNG DES HINTERRAD-BREMSBELAGPLATTE ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE 9 Déposer la goupille de plaquette 9 Togliere la spina della pastiglia 6 9 Bremsbelagstift 6 und Bremsbelä- 6 et les plaquettes de frein 7.
• Page 178
  REAR BRAKE PAD INSULATOR INSPECTION INSP BRAKE FLUID LEVEL INSPECTION EC36b000 REAR BRAKE PAD INSULATOR INSPECTION 1. Remove: 9 Brake pad Refer to “REAR BRAKE PAD INSPEC- TION AND REPLACEMENT” section. 2. Inspect: 9 Rear brake pad insulator 1 Damage ¡ Replace. EC367001 BRAKE FLUID LEVEL INSPECTION 1.
• Page 179
  VERIFICATION DE L’ISOLANT DE LA PLAQUETTE DE FREIN ARRIERE/VERIFICATION DU NIVEAU DU LIQUIDE DE FREIN INSPEKTION DER ISOLIERUNG DES HINTERRADBREMSBELAGS/INSPEKTION DES INSP BREMSFLÜSSIGKEITSSTANDESS ISPEZIONE DELL’ISOLATORE DELLA PASTIGLIA DEL FRENO POSTERIORE/ISPEZIONE DEL LIVELLO DEL LIQUIDO PER FRENI IC36b000 VERIFICATION DE L’ISOLANT INSPEKTION ISOLIERUNG ISPEZIONE…
• Page 180
  INSP SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION EC368000 SPROCKETS INSPECTION 1. Inspect: 9 Sprocket teeth a Excessive wear ¡ Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set. EC369002 DRIVE CHAIN INSPECTION 1. Remove: 9 Master link clip 9 Joint 1 9 Drive chain 2 2.
• Page 181
  VERIFICATION DES PIGNONS/VERIFICATION DE LA CHAINE DE TRANSMISSION INSP INSPEKTION DER KETTENRÄDER/INSPEKTION DER ANTRIEBSKETTE ISPEZIONE DEI ROCCHETTI/ ISPEZIONE DELLA CATENA DI TRASMISSIONE IC368000 VERIFICATION DES PIGNONS INSPEKTION DER KETTENRÄDER ISPEZIONE DEI ROCCHETTI 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Dent de pignon a 9 Kettenradzahn a 9 Denti dei rocchetti a ¡…
• Page 182
  INSP DRIVE CHAIN SLACK ADJUSTMENT 5. Install: 9 Drive chain 1 9 Joint 2 9 Master link clip 3 Be sure to install the master link clip to the direction as shown. a Turning direction 6. Lubricate: 9 Drive chain Drive chain lubricant: SAE 10W-30 motor oil or suitable chain lubricants…
• Page 183
  REGLAGE DE LA FLECHE DE CHAINE DE TRANSMISSION INSP EINSTELLUNG DES ANTRIEBSKETTENDURCHHANGES REGOLAZIONE DEL GIOCO DELLA CATENA DI TRASMISSIONE 5. Monter: 5. Installare: 5. Einbauen: 9 Chaîne de transmission 1 9 Catena di trasmissione 1 9 Antriebskette 1 9 Raccord 2 9 Giunto 2 9 Verbindung 2 9 Agrafe de l’attache rapide 3…
• Page 184
  INSP FRONT FORK INSPECTION 3. Adjust: 9 Drive chain slack Drive chain slack adjustment steps: 9 Loosen the axle nut 1 and locknuts 2. 9 Adjust chain slack turning adjusters 3. To tighten ¡ Turn adjuster 3 3 counter- clockwise. To loosen ¡…
• Page 185
  VERIFICATION DE LA FOURCHE AVANT INSP INSPEKTION DER VORDERRADGABEL ISPEZIONE DELLA FORCELLA ANTERIORE 3. Régler: 3. Regolare: 3. Einstellen: 9 Flèche de chaîne de transmis- 9 Gioco della catena di trasmis- 9 Antriebskettendurchhang sion sione Einstellschritte des Antriebsket- Procédure de réglage de flèche de Passi della regolazione del gioco tendurchhands: chaîne de transmission:…
• Page 186
  FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ INSP FRONT FORK INTERNAL PRESSURE RELIEVING/ FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1. Remove: 9 Protector 9 Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.
• Page 187
  NETTOYAGE DE BAGUE D’ETANCHETTE ET DE JOINT ANTIPOUSSIERE DE FOURCHE AVANT/ DECOMPRESSION INTERNE DE LA FOURCHE AVANT/ REGLAGE DE LA FORCE D’AMORTISSEMENT DE REBOND DE LA FOURCHE AVANT REINIGUNG DER ÖLDICHTUNG UND STAUBDICHTUNG DER VORDERRADGABEL/ VORDERRADGABEL-INNENDRUCKENTLASTUNG/ INSP EINSTELLUNG DER EXPANSIONS-DÄMPFUNGSKRAFT DER VORDERRADGABEL PULITURA DEL PARAOLIO E DEL PARAPOLVERE DELLA FORCELLA ANTERIORE/ COMPENSAZIONE DELLA PRESSIONE INTERNA DELLA FORCELLA ANTERIORE/ REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELL’ESTENSIONE DELLA FORCELLA ANTERIORE…
• Page 188
  FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT Extent of adjustment: Maximum Minimum 20 clicks out Fully turned in (from maximum position position) 9 STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.
• Page 189
  REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION DE LA FOURCHE AVANT INSP EINSTELLUNG DER KOMPRESSIONS-DÄMPFUNGSKRAFT DER VORDERRADGABEL REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELLA COMPRES- SIONE DELLA FORCELLA ANTERIORE Ampiezza della Einstellumfang: Etendue de réglage: regolazione: Maximum Minimum Maximum Minimum Massima Minima Voll 20 Raststellungen…

• Page 190: Rear Shock Absorber Inspection

  INSP REAR SHOCK ABSORBER INSPECTION Extent of adjustment: Maximum Minimum 20 clicks out Fully turned in (from maximum position position) 9 STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.

• Page 191
  VERIFICATION DE L’AMORTISSEUR ARRIERE INSP INSPEKTION DES HINTERRAD-STOSSDÄMPFERS ISPEZIONE DELL’AMMORTIZZATORE POSTERIORE Ampiezza della Einstellumfang: Etendue de réglage: regolazione: Maximum Minimum Maximum Minimum Massima Minima Voll 20 Raststellungen Position 20 le mettre hors Posizione 20 scatti in senso hineingedrehten herausdrehen complètement circuit (à…
• Page 192
  REAR SHOCK ABSORBER SPRING PRELOAD INSP ADJUSTMENT EC36M014 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Remove: 9 Rear frame 3. Loosen: 9 Locknut 1 4. Adjust: 9 Spring preload By turning the adjuster 2.
• Page 193
  REGLAGE DE LA PRECONTRAINTE DE RESSORT DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER FEDERVORSPANNUNG DES HINTERRAD-STOSSDÄMPFERS INSP REGOLAZIONE DEL PRECARICO DELLA MOLLA DELL’AMMORTIZZATORE POSTERIORE IC36M014 REGLAGE PRECON- EINSTELLUNG DER FEDERVOR- REGOLAZIONE DEL PRECARICO TRAINTE RESSORT SPANNUNG HINTERRAD- DELLA MOLLA DELL’AMMOR- L’AMORTISSEUR ARRIERE STOSSDÄMPFERS TIZZATORE POSTERIORE 1.
• Page 194
  REAR SHOCK ABSORBER REBOUND DAMPING INSP FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: 9 Rebound damping force By turning the adjuster 1. Stiffer a a ¡ Increase the rebound damping force. (Turn the adjuster 1 1 in.) Softer b b ¡…
• Page 195
  REGLAGE DE LA FORCE D’AMORTISSEMENT DE REBOND DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER EXPANSIONS-DÄMPFUNGSKRAFT DES INSP HINTERRAD-STOSSDÄMPFERS REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELL’ESTENSIONE DELL’AMMORTIZZATORE POSTERIORE IC36N020 REGLAGE FORCE EINSTELLUNG DER EXPANSIONS- REGOL‹ELLA FORZA DI SMOR- D’AMORTISSEMENT DÄMPFUNGSKRAFT DES HINTER- ZAMENTO DELL’ESTENSIONE REBOND DE L’AMORTISSEUR RAD-STOSSDÄMPFERS D E L L ’…
• Page 196
  REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: 9 Low compression damping force By turning the adjuster 1. Stiffer a a ¡ Increase the low compression damping force. (Turn the ad- juster 1 1 in.) Softer b b ¡…
• Page 197
  REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION BASSE DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER NIEDRIGEN KOMPRESSIONS-DÄMPFUNGSKRAFT DES HINTERRADSTOSSDÄMPFFRS INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO A BASSA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE IC36c000 REGLAGE FORCE EINSTELLUNG NIEDRIGEN REGOLAZIONE DELLA FORZA D’AMORTISSEMENT DE COM- KOMPRESSIONS-DÄMPFUNGS- DI SMORZAMENTO A BASSA PRESSION BASSE DE L’AMOR- KRAFT…
• Page 198
  REAR SHOCK ABSORBER HIGH COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: 9 High compression damping force By turning the adjuster 1. Stiffer a a ¡ Increase the high compression damping force. (Turn the ad- juster 1 1 in.) Softer b b ¡…
• Page 199
  REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION ELEVEE DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER HOHEN KOMPRESSIONS-DÄMPFUNGSKRAFT DES HINTERRADSTOSSDÄMPFFRS INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE IC36d000 REGLAGE FORCE EINSTELLUNG DER HOHEN KOM- REGOLAZIONE DELLA FORZA D’AMORTISSEMENT DE COM- PRESSIONS-DÄMPFUNGSKRAFT DI SMORZAMENTO AD ALTA PRESSION ELEVEE DE L’AMOR-…
• Page 200
  TIRE PRESSURE CHECK/SPOKES INSPECTION AND INSP TIGHTENING/WHEEL INSPECTION EC36Q001 TIRE PRESSURE CHECK 1. Measure: 9 Tire pressure Out of specification ¡ Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm , 15 psi) NOTE: 9 Check the tire while it is cold. 9 Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
• Page 201
  CONTROLE DE PRESSION DES PNEUS/VERIFICATION ET SERRAGE DES RAYONS/VERIFICATION DE LA ROUE PRÜFUNG DES REIFENDRUCKS/INSPEKTION UND FESTZIEHEN DER INSP SPEICHEN/INSPEKTION DES RADES CONTROLLO DELLA PRESSIONE DEGLI PNEUMATICI/ ISPEZIONE E SERRAGGIO DEI RAGGI/ ISPEZIONE DELLE RUOTE IC36Q001 CONTROLE DE PRESSION DES PRÜFUNG DES REIFENDRUCKS CONTROLLO DELLA PRESSIONE PNEUS…
• Page 202
  INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: 9 Bearing free play Exist play ¡ Replace. EC36U014 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: 9 Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth.
• Page 203
  VERIFICATION ET REGLAGE DE LA TETE DE FOURCHE INSP INSPEKTION UND EINSTELLUNG DES LENKERKOPFES ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO 2. Examiner: 2. Ispezionare: 2. Prüfen: 9 Jeu de roulement 9 Gioco del cuscinetto 9 Lagerspiel Ily a du jeu ¡ Changer. Esiste gioco ¡…
• Page 204
  INSP STEERING HEAD INSPECTION AND ADJUSTMENT Ring nut wrench: YU-33975/90890-01403 Ring nut (initial tightening): 38 Nm (3.8 m•kg, 27ft•lb) 9 Loosen the ring nut one turn. 9 Retighten the ring nut using the ring nut wrench. Avoid over-tightening. Ring nut (final tightening): 7 Nm (0.7 m•kg, 5.1 ft•lb) 9 Check the steering shaft by turning it lock to lock.
• Page 205
  VERIFICATION ET REGLAGE DE LA TETE DE FOURCHE INSP INSPEKTION UND EINSTELLUNG DES LENKERKOPFES ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO Clé pour écrou annulaire: Ringmutterschlüssel: Chiave per ghiera: YU-33975/90890-01403 YU-33975/90890-01403 YU-33975/90890-01403 Ecrou annulaire (serrage Ghiera Ringmutter initial): (serraggio iniziale): (anfängliches 38 Nm (3,8 m•kg, 27 ft•lb) 38 Nm (3,8 m•kg, 27 ft•lb)
• Page 206
  INSP LUBRICATION EC36a042 LUBRICATION Å Use Yamaha cable lube or equivalent on To ensure smooth operation of all components, these areas. lubricate your machine during setup, after break- ı Use SAE10W-30 motor oil or suitable chain in, and after every race.
• Page 207
  9 Gasseilende 0 Estremità del cavo della frizione 0 Extrémités des câbles d’embrayage 0 Kupplungsseilenden A Usare lubrificante per cavi Yamaha o A Mettre du lubrifiant Yamaha pour A Yamaha Seilung-Schmiermittel oder equivalente su queste zone. câbles, ou équivalent sur ces parties.

• Page 208: Electrical

  INSP ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: 9 Spark plug 2. Inspect: 9 Electrode 1 Wear/Damage ¡ Replace. 9 Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color ¡ Check the engine condition.

• Page 209: Moteur

  PARTIE ELECTRIQUE/VERIFICATION DE LA BOUGIE INSP ELEKTRISCHE EINRICHTUNGEN/INSPEKTION DER ZÜNDKERZE PARTE ELETTRICA/ ISPEZIONE DELLA CANDELA IC370000 PARTIE ELECTRIQUE ELEKTRISCHE PARTE ELETTRICA VERIFICATION DE LA BOUGIE EINRICHTUNGEN IC371001 1. Déposer: ISPEZIONE DELLA CANDELA INSPEKTION DER ZÜNDKERZE 9 Bougie 1. Togliere: 1. Ausbauen: 2.

• Page 210
  INSP IGNITION TIMING CHECK EC372012 IGNITION TIMING CHECK 1. Remove: 9 Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. 9 Spark plug 9 Crankcase cover (left) 2. Attach: 9 Dial gauge 1 9 Spark plug hole dial stand 2 Dial gauge: YU-3097/90890-01252 Spark plug hole dial stand:…
• Page 211
  CONTROLE ET REGLAGE DE L’AVANCE A L’ALLUMAGE INSP PRÜFUNG UND EINSTELLUNG DER ZÜNDZEITPUNKT CONTROLLO DELLA MESSA IN FASE DELL’ACCENSIONE IC372012 CONTROLE ET REGLAGE DE PRÜFUNG EINSTELLUNG CONTROLLO DELLA MESSA IN L’AVANCE A L’ALLUMAGE DER ZÜNDZEITPUNKT FASE DELL’ACCENSIONE 1. Déposer: 1. Ausbauen: 1.
• Page 212
  INSP IGNITION TIMING CHECK 7. Adjust: 9 Ignition timing Adjustment steps: 9 Loosen the screws (stator) 1. 9 Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator. 9 Tighten the screws (stator). Screw (stator): 8 Nm (0.8 m•kg, 5.8 ft•lb) 3-40…
• Page 213
  CONTROLE ET REGLAGE DE L’AVANCE A L’ALLUMAGE INSP PRÜFUNG UND EINSTELLUNG DER ZÜNDZEITPUNKT CONTROLLO DELLA MESSA IN FASE DELL’ACCENSIONE 7. Régler: 7. Regolare: 7. Einstellen: 9 Avance à l’allumage 9 Messa in fase dell’accensione 9 Zündzeitpunkt Procédure de réglage: Passi della regolazione: Einstellschritte: 9 Desserrer les vis (stator) 1.
• Page 214
  SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS 19 Nm (1.9 m•kg, 13 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 19 Nm (1.9 m•kg, 13 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb)
• Page 215
  SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX SITZ, KRAFTSTOFFTANK UND SEITENDECKEL SELLA, SERBATOIO DEL CARBURANTE E COPERTURE LATERALI MOTEUR SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX 1 Dépose du selle 2 Dépose du réservoir à essence Etendue de dépose: 3 Dépose des couvercles latéraux 4 Dépose de la plaque d’immatriculation Etendue de dépose Ordre…
• Page 216
  SEAT, FUEL TANK AND SIDE COVERS EC4R3000 REMOVAL POINTS EC413110 Side cover 1. Remove: 9 Bolt (side cover) 9 Side cover (left and right) 1 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air cleaner case.
• Page 217
  SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX SITZ, KRAFTSTOFFTANK UND SEITENDECKEL SELLA, SERBATOIO DEL CARBURANTE E COPERTURE LATERALI IC4R3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC413110 Couvercle latéral Seitendeckel Copertura laterale 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Boulon (couvercle latéral) 9 Bullone (copertura laterale) 9 Schraube (seitendeckel) 9 Couvercle latéral (gauche et…

• Page 218: Exhaust Pipe And Silencer

  EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER 11 Nm (1.1 m•kg, 8.0 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 1 Silencer removal 2 Exhaust pipe removal Extent of removal:…

• Page 219: Tubo Di Scarico E Silenziatore

  TUYAU D’ECHAPPEMENT ET SILENCIEUX AUSPUFFROHR UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE TUYAU D’ECHAPPEMENT ET SILENCIEUX 1 Dépose du silencieux 2 Dépose du tuyau déchappement Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU TUYAU DéCHAPPEMENT ET DU SILENCIEUX Préparation…

• Page 220: Radiator

  RADIATOR EC450001 RADIATOR 1 Nm (0.1 m•kg, 0.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 1 Radiator removal Extent of removal: Extent of removal Order…

• Page 221
  RADIATEUR KÜHLER RADIATORE RADIATEUR 1 Dépose du radiateur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU RADIATEUR Vidanger le liquide de refroidissement. Se reporter à la section “CHANGEMENT DU Préparation LIQUIDE DE REFROIDISSEMENT” du pour la dépose CHAPITRE 3.
• Page 222
  RADIATOR EC456000 HANDLING NOTE Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counter-…
• Page 223
  RADIATEUR KÜHLER RADIATORE IC456000 REMARQUES HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO CONCERNANT LA MANIPULATION Wenn der Motor und der Kühler Non togliere il tappo del radiatore heiß sind, darf niemals der Künler- quando il motore e il radiatore sono deckel entfernt werden. Brühend caldi.
• Page 224
  RADIATOR EC455000 ASSEMBLY AND INSTALLATION EC445353 Radiator 1. Install: 9 Radiator breather hose 1 9 Radiator hose 2 2 1 Nm (0.1 m•kg, 0.7 ft•lb) To radiator (right) 3. 2. Install: 9 Radiator (right) 1 9 Bolt [radiator (right)] 2 10 Nm (1.0 m•kg, 7.2 ft•lb) 9 Radiator hose 4 3 1 Nm (0.1 m•kg, 0.7 ft•lb)
• Page 225
  RADIATEUR KÜHLER RADIATORE IC455000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E Kühler MONTAGE INSTALLAZIONE 1. Einbauen: Radiateur IC445353 9 Kühler-Belüftungsschlauch 1 1. Monter: Radiatore 9 Kühlerschlauch 2 2 9 Tuyau de reniflard de radiateur 1. Installare: 9 Sfiato del radiatore 1 1 Nm (0,1 m•kg, 0,7 ft•lb) 9 Tuyau de radiateur 2 2 9 Manicotto flessibile del radiato-…

• Page 226: Carburetor And Reed Valve

  CARBURETOR AND REED VALVE EC460000 CARBURETOR AND REED VALVE 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 1 Carburetor removal 2 Reed valve removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR AND REED VALVE REMOVAL Preparation for Fuel tank…

• Page 227: Vergaser Und Zungenventil

  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA CARBURATEUR ET SOUPAPE FLEXIBLE 1 Dépose du carburateur 2 Dépose de la soupape flexible Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU CARBURATEUR ET DE LA SOUPAPE FLEXIBLE Préparation Réservoir à…

• Page 228
  CARBURETOR AND REED VALVE EC468000 CARBURETOR DISASSEMBLY 1 Carburetor disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Mixing chamber top Throttle valve Refer to “REMOVAL POINTS”. Needle holder Jet needle Float chamber Float pin Float Needle valve Main jet…
• Page 229
  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA DEMONTAGE DU CARBURATEUR 1 Démontage du carburateur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEMONTAGE DU CARBURATEUR Haut de chambre de mélange Boisseau Se reporter à…
• Page 230
  CARBURETOR AND REED VALVE EC466020 HANDLING NOTE Do not loosen the screws {TPS (throttle position sensor)} except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. EC463000 REMOVAL POINTS EC463110 Throttle valve 1.
• Page 231
  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC466020 HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO REMARQUES CONCERNANT LA MANIPULATION Schrauben des TPS-Leitungskabels Non allentare le viti [conduttore TPS (Drosselstellungssensor) nur dann (sensore di posizione gas)] se non per lösen wenn das TPS-Leitungskabel cambiare il conduttore TPS (sensore Ne pas desserrer les vis du fil du cap-…
• Page 232
  CARBURETOR AND REED VALVE EC464000 INSPECTION EC464130 Carburetor 1. Inspect: 9 Carburetor body Contamination ¡ Clean. NOTE: 9 Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. 9 Never use a wire. 2.
• Page 233
  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC464000 VERIFICATION INSPEKTION ISPEZIONE IC464130 Carburateur Vergaser Carburatore 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Corps du carburateur 9 Corpo del carburatore 9 Vergasergehäuse Contaminazione ¡ Pulirlo. Encrassé¡Nettoyer. Verschmutzung¡Reinigen.
• Page 234
  CARBURETOR AND REED VALVE EC464401 Jet needle 1. Inspect: 9 Jet needle 1 Bends/Wear ¡ Replace. 9 Clip groove Free play exists/Wear ¡ Replace. 9 Clip position Standard clip position: No.2 Groove *No.3 Groove *For EUROPE EC464511 Float height 1. Measure: 9 Float height a Out of specification ¡…
• Page 235
  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC464401 Aiguille Ago a getto Düsennadel 1. Examiner: 1. Ispezionare: 1. Prüfen: 9 Aiguille 1 9 Ago a getto 1 9 Düsennadel 1 Déformée/usure¡Changer. Curvature/Usura¡Sostituirlo. Biegung/Verschleiß¡Erneu- 9 Groove du circlips 9 Scanalatura del fermaglio a ern.
• Page 236
  CARBURETOR AND REED VALVE EC464600 Float 1. Inspect: 9 Float 1 Damage ¡ Replace. EC464701 Reed valve 1. Measure: 9 Reed valve bending a Out of specification ¡ Replace. Reed valve bending limit: 0.2 mm (0.008 in) 9 Valve stopper height b Out of specification ¡…
• Page 237
  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC464600 Flotteur Galleggiante Schwimmer 1. Examiner: 1. Ispezionare 1. Prüfen: 9 Flotteur 1 9 Galleggiante 1 9 Schwimmer 1 Endommagement¡Changer. Danni¡Sostituirlo. Beschädigung¡Erneuern. IC464701 Soupape flexible Zungenventil Valvola a lamella 1.
• Page 238
  CARBURETOR AND REED VALVE 2. Install: 9 Gasket (reed valve) 1 9 Plate (reed valve) 2 9 Reed valve assembly 3 9 Reed valve spacer 4 NOTE: 9 Install the gasket (reed valve) with its projection a to the left. 9 Install the reed valve spacer with its chamfered side b to the right.
• Page 239
  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 2. Monter: 2. Installare: 2. Einbauen: 9 Guarnizione (valvola a lamella) 9 Joint (soupape flexible) 1 9 Dichtung (Zungenventil) 9 Plaquette (soupape flexible) 2 9 Distanziale (valvola a lamella) 9 Ens.
• Page 240
  CARBURETOR AND REED VALVE 2. Install: 9 O-ring 1 9 Solenoid valve 2 9 Clamp 3 9 Screw (clamp) 4 To carburetor 5. 9 Before installing the solenoid valve, blow air on the solenoid valve and its installing location on the carburetor in order to remove any foreign particles such as chips etc.
• Page 241
  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 2. Monter: 2. Installare: 2. Einbauen: 9 Joint torique 1 9 Anello di tenuta 1 9 O-Ring 1 9 Electrovanne 2 9 Elettrovalvola 2 9 Magnetventil 2 9 Bride 3 9 Brida 3 9 Klemme 3 9 Vis (bride) 4…
• Page 242
  CARBURETOR AND REED VALVE 6. Install: 9 Needle valve 1 9 Float 2 9 Float pin 3 NOTE: 9 After installing the needle valve to the float, install them to the carburetor. 9 Check the float for smooth movement. 7. Install: 9 Float chamber 1 9 Plate 2 9 Screw (float chamber) 3…
• Page 243
  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 6. Monter: 6. Installare: 6. Einbauen: 9 Pointeau 1 9 Valvola ad ago 1 9 Nadelventil 1 9 Flotteur 2 9 Galleggiante 2 9 Schwimmer 2 9 Axe de flotteur 3 9 Perno del galleggiante 3 9 Schwimmerstift 3 HINWEIS:…
• Page 244
  CARBURETOR AND REED VALVE 10. Install: 9 Throttle cable 1 9 Mixing chamber top 2 9 Spring (throttle valve) 3 9 Ring 4 9 Throttle valve 5 NOTE: 9 While compressing the spring, connect the throttle cable. 9 Align the projection a on the ring with the groove b in the needle holder 6.
• Page 245
  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 10. Monter: 10. Installare: 10. Einbauen: 9 Câble d’accélérateur 1 9 Cavo dell’acceleratore 1 9 Gasseil 1 9 Haut de chambre de mélange 2 9 Parte superiore del diffusore 2 9 Mischkammer-Oberteil 2 9 Ressort (boisseau) 3 9 Molla (valvola regolatrice del…
• Page 246
  CARBURETOR AND REED VALVE 2. Tighten: 9 Screw (carburetor joint) 1 3. Tighten: 9 Screw (air cleaner joint) 1 NOTE: Place the screw head a with its top as shown and secure the clamp in alignment with the hori- zontal line b that passes the center of the car- buretor bore.
• Page 247
  CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 2. Serrer: 2. Serrare: 2. Festziehen: 9 Vis (raccord du carburateur ) 1 9 Vite (giunto del carburatore) 1 9 Schraube (Vergaserverbin- dung) 1 3. Serrer: 3. Festziehen: 3.

• Page 248: Cylinder Head , Cylinder And Piston

  CYLINDER HEAD, CYLINDER AND PISTON EC470000 CYLINDER HEAD, CYLINDER AND PISTON EC478000 CYLINDER HEAD AND CYLINDER 34 Nm (3.4 m•kg, 24 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 42 Nm (4.2 m•kg, 30 ft•lb)

• Page 249
  CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE CULASSE, CYLINDRE ET PISTON CULASSE ET CYLINDRE 1 Dépose de la culasse 2 Dépose du cylindre Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA CULASSE ET DU CYLINDRE…
• Page 250
  CYLINDER HEAD, CYLINDER AND PISTON EC478100 PISTON AND POWER VALVE 6 Nm (0.6 m•kg, 4.3 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Piston and piston ring removal 2 Power valve removal Extent of removal:…
• Page 251
  CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE PISTON ET CLAPET DE PUISSANCE 1 Dépose du piston et segment 2 Dépose du clapet puissance Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU PISTON ET CLAPET DE PUISSANCE…
• Page 252
  CYLINDER HEAD, CYLINDER AND PISTON EC473000 REMOVAL POINTS EC473220 Push rod 1. Remove: 9 Bolt (push rod) 1 9 Push rod 2 NOTE: Insert the set pin 3 included in owner’s tool kit to remove the bolt (push rod). Be sure to use the set pin. If the set pin is not used, the power valve constituent parts will result in damage.
• Page 253
  CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC473000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC473220 Champignon de débrayage Schubstange Asta di spinta 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Boulon (champignon de débra- 9 Bullone (asta di spinta) 1 9 Schraube (Schubstange) 1 yage) 1…
• Page 254
  CYLINDER HEAD, CYLINDER AND PISTON 3. Remove: 9 Piston ring 1 NOTE: Take care not to scratch the piston or damage the piston ring by expanding it more than neces- sary. EC474000 INSPECTION EC474102 Cylinder head 1. Eliminate: 9 Carbon deposits Use a rounded scraper 1.
• Page 255
  CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 3. Déposer: 3. Ausbauen: 3. Togliere: 9 Segment 1 9 Fascia elastica 1 9 Kolbenring 1 HINWEIS: N.B.: NOTA: Veillez à ne pas rayer le piston et à ne Darauf achten, den Kolben nicht zu Attenzione a non graffiare il pistone o endommager…
• Page 256
  CYLINDER HEAD, CYLINDER AND PISTON EC474201 Cylinder 1. Eliminate: 9 Carbon deposits Use a rounded scraper 1. NOTE: Do not use a sharp instrument. Avoid scratching the aluminum. 2. Inspect: 9 Cylinder inner surface Score marks ¡ Repair or replace. Use #400~600 grit wet sandpaper.
• Page 257
  CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474201 Zylinder Cilindro Cylindre 1. Entfernen: 1. Eliminare: 1. Éliminer: 9 Ölkohleablagerungen 9 Depositi carboniosi 9 Dépôts du carbone Utiliser le grattoir arrondi 1. Einem abgerundeten Schaber Usare un raschietto arrotondato verwenden 1.
• Page 258
  CYLINDER HEAD, CYLINDER AND PISTON 3. Measure: 9 Piston skirt diameter Use micrometer 1. Measure the specific distance b from the stepped surface a on inside of the piston. Out of specification ¡ Replace. Distance b b Piston dia. 17.5 mm 66.352~66.367 mm (0.69 in) (2.6120~2.6129 in)
• Page 259
  CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 3. Mesurer: 3. Messen: 3. Misurare: 9 Diamètre de la jupe de piston 9 Diametro della fascia di guida 9 Durchmesser des Kolbenman- Utiliser le micromètre 1. tels del pistone Usare un micrometro 1.
• Page 260
  CYLINDER HEAD, CYLINDER AND PISTON 5. Check: 9 Free play There should be no noticeable free play. Free play exists ¡ Inspect the connecting rod for wear/Replace the pin and/or con- necting rod as required. EC474502 Piston ring 1. Install: 9 Piston ring Into the cylinder.
• Page 261
  CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 5. Prüfen: 5. Contrôler: 5. Controllare: 9 Spiel 9 Jeu 9 Gioco Es sollte kein spürbares Spiel Il ne doit pas y avoir de jeu Non dovrebbe esservi gioco sein.
• Page 262
  CYLINDER HEAD, CYLINDER AND PISTON EC474602 Piston clearance 1. Calculate: 9 Piston clearance Out of limit ¡ Replace piston, and piston ring and/or cylinder. Refer to “Cylinder” and “Piston”. PISTON CYLINDER PISTON – CLEARANCE BORE DIAMETER Piston clearance: Standard <Limit> 0.045~0.050 mm 0.1 mm (0.0018~0.0020 in)
• Page 263
  CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474602 Jeu de piston Gioco del pistone Kolbenspiel 1. Calculer: 1. Calcolare 1. Berechnen: 9 Jeu de piston 9 Gioco del pistone 9 Kolbenspiel Hors limite¡Changer le piston, Fuori limite¡Sostituire il pisto- Außerhalb des Grenzwertes ¡Kolben,…
• Page 264
  CYLINDER HEAD, CYLINDER AND PISTON 3. Combination: Combine the piston and cylinder by the fol- lowing chart. Cylinder mark Piston mark (color) A (red) B (orange) C (green) D (purple) NOTE: When you purchase a cylinder, you cannot des- ignate its size. Choose the piston that matches the above chart.
• Page 265
  CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 3. Combinaison: 3. Kombination: 3. Combinazione: Combiner le piston et le cylindre à Kolben Zylinder gemäß Combinare il pistone e il cilindro l’aide du tableau suivant. nachfolgender Tabelle kombinie- in base alla tabella che segue.
• Page 266
  CYLINDER HEAD, CYLINDER AND PISTON EC475000 ASSEMBLY AND INSTALLATION EC475193 Power valve 1. Install: 9 Power valve 1 1 9 Valve holder 2 2 9 Bolt (valve holder 2) 3 6 Nm (0.6 m•kg, 4.3 ft•lb) NOTE: 9 Install the power valve 1 with its gouge a fac- ing upside.
• Page 267
  CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC475000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E Leistungsventil MONTAGE INSTALLAZIONE 1. Einbauen: Clapet de puissance IC475193 9 Leistungsventil 1 1 1. Monter: Valvola di potenza 9 Ventilhalterung 2 2 9 Clapet de puissance 1 1 1.
• Page 268
  CYLINDER HEAD, CYLINDER AND PISTON 4. Install: 9 Spring 1 1 9 Link lever 2 9 Pulley 3 9 Spring 2 4 9 Plain washer 5 9 Valve shaft 6 NOTE: 9 Install the spring 1 to the link lever, and then to the cylinder.
• Page 269
  CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 4. Monter: 4. Einbauen: 4. Installare: 9 Ressort 1 1 9 Molla 1 1 9 Feder 1 1 9 Levier articulé 2 9 Leva del biscottino 2 9 Verbindungshebel 2 9 Poulie 3 9 Puleggia 3…
• Page 270
  CYLINDER HEAD, CYLINDER AND PISTON 7. Install: 9 O-ring 1 9 Side holder 2 9 Screw (side holder) 3 4 Nm (0.4 m•kg, 2.9 ft•lb) 9 YPVS breather hose 4 NOTE: 9 Apply the lithium soap base grease on the O- rings.
• Page 271
  CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 7. Monter: 7. Einbauen: 7. Installare: 9 Joint torique 1 9 Anello di tenuta 1 9 O-ring 1 9 Béquille latérale 2 9 Supporto laterale 2 9 Seitenhalterung 2 9 Vis (béquille latérale) 3 9 Vite (supporto laterale) 3 9 Schraube (Seitenhalterung) 3…
• Page 272
  CYLINDER HEAD, CYLINDER AND PISTON 3. Install: 9 Piston 1 9 Piston pin 2 9 Piston pin clip 3 NOTE: 9 The arrow a on the piston dome must point to exhaust side. 9 Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the pis- ton pin clip from falling into the crankcase cavi- Do not allow the clip open ends to meet the…
• Page 273
  CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 3. Monter: 3. Ausbauen: 3. Installare: 9 Piston 1 9 Pistone 1 9 Kolben 1 9 Axe de piston 2 9 Spinotto 2 9 Kolbenbolzen 2 9 Agrafe de l’axe de piston 3 9 Fermaglio a graffa dello spinot- 9 Klemme des Kolbenbolzens 3 to 3…
• Page 274
  CYLINDER HEAD, CYLINDER AND PISTON 4. Install: 9 Push rod 1 9 Bolt (push rod) 2 5 Nm (0.5 m•kg, 3.6 ft•lb) NOTE: 9 Insert the set pin 3 included in owner’s tool kit to install the bolt (push rod). 9 Do not forget to remove the set pin.
• Page 275
  CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 4. Monter: 4. Installare: 4. Einbauen: 9 Champignon de débrayage 1 9 Asta di spinta 1 9 Schubstange 1 9 Boulon (champignon de débra- 9 Bullone (asta di spinta) 2 9 Schraube (Schubstange) 2 yage) 2 5 Nm (0,5 m•kg, 3,6 ft•lb)
• Page 276
  CYLINDER HEAD, CYLINDER AND PISTON 8. Install: 9 Engine bracket 1 9 Bolt (engine bracket) 2 34 Nm (3.4 m•kg, 24 ft•lb) 9 Engine mounting bolt (upper) 3 69 Nm (6.9 m•kg, 50 ft•lb) NOTE: Install the engine bracket with its damper a on the right side of the body.
• Page 277
  CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 8. Installare: 8. Einbauen: 8. Monter: 9 Staffa del motore 1 9 Motorhalterung 1 9 Support du moteur 1 9 Bullone (staffa del motore 2 9 Schraube (Motorhalterung) 2 9 Boulon (support du moteur) 2 34 Nm (3,4 m•kg, 24 ft•lb) 34 Nm (3,4 m•kg, 24 ft•lb)

• Page 278: Clutch And Primary Driven Gear

  CLUTCH AND PRIMARY DRIVEN GEAR EC490000 CLUTCH AND PRIMARY DRIVEN GEAR EC498000 CLUTCH PLATE AND FRICTION PLATE 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Clutch plate and friction plate removal Extent of removal: Extent of removal Order Part name Q’ty…

• Page 279
  EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO EMBRAYAGE ET PIGNON MENE PRIMAIRE DISQUE D’EMBRAYAGE ET DISQUE DE FRICTION 1 Dépose du disque d’embrayage et du disque de friction Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té…
• Page 280
  CLUTCH AND PRIMARY DRIVEN GEAR EC498200 PRIMARY DRIVEN GEAR, PUSH ROD AND PUSH LEVER AXLE 75 Nm (7.5 m•kg, 54 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 1 Push rod and push lever axle removal 2 Push rod 1 disassembly Extent of removal: 3 Primary driven gear removal Extent of removal…
• Page 281
  EMBRAYAGE ET PISGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO PIGNON MENE PRIMAIRE, CHAMPINGNON DE DEBRAYAGE ET AXE DE LEVIER DE POUSSE 1 Dépose de champignon de débrayage et de l’axe de levier de poussé Etendue de dépose: 2 Demontage de champignon de débrayage 1 3 Dépose du pignon mené…
• Page 282
  CLUTCH AND PRIMARY DRIVEN GEAR å å EC493000 REMOVAL POINTS EC483211 Clutch boss 1. Remove: 9 Nut 1 9 Lock washer 2 9 Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4, 5 to hold the clutch boss. ∫…
• Page 283
  EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC493000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC483211 Noix d’embrayage Kupplungsnabe Mozzo della frizione 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Ecrou 1 9 Dado 1 9 Mutter 1 9 Rondelle-frein 2 9 Rosetta di sicurezza 2…
• Page 284
  CLUTCH AND PRIMARY DRIVEN GEAR EC484500 Friction plate 1. Measure: 9 Friction plate thickness Out of specification ¡ Replace friction plate as a set. Measure at all four points. Friction plate thickness: Standard <Limit> 2.9~3.1 mm 2.8 mm (0.114~0.122 in) (0.110 in) EC484600 Clutch plate…
• Page 285
  EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC484500 Disque de friction Disco di innesto Reibscheibe 1. Mesurer: 1. Misurare: 1. Messen: 9 Epaisseur de disque de friction 9 Spessore del disco di innesto 9 Reibscheibendicke Hors-spécification¡…
• Page 286
  CLUTCH AND PRIMARY DRIVEN GEAR EC495230 Clutch 1. Install: 9 Thrust plate [D=ø 42 mm (1.65 in)] 1 9 Spacer 2 9 Bearing 3 9 Primary driven gear 4 NOTE: Apply the transmission oil on the bearing, spacer and primary driven gear inner circumference. 2.
• Page 287
  EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC495230 Embrayage Frizione Kupplung 1. Monter: 1. Installare: 1. Einbauen: 9 Plaque de botée [D=ø42mm 9 Disco di spinta [D=ø42 mm 9 Druckscheibe [D=ø42 (1,65 in)] 1 (1,65 in)] 1 (1,65 in)] 1 9 Entretoise 2…
• Page 288
  CLUTCH AND PRIMARY DRIVEN GEAR 5. Install: 9 Friction plate 1 9 Clutch plate 2 NOTE: 9 Install the clutch plates and friction plates alter- nately on the clutch boss, starting with a friction plate and ending with a friction plate. 9 Apply the transmission oil on the friction plates and clutch plates.
• Page 289
  EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO 5. Monter: 5. Installare: 5. Einbauen: 9 Disque de friction 1 9 Disco di innesto 1 9 Reibscheibe 1 9 Disque d’embrayage 2 9 Disco della frizione 2 9 Kupplungsscheibe 2 HINWEIS: N.B.:…
• Page 290
  CLUTCH AND PRIMARY DRIVEN GEAR 10. Install: 9 O-ring 1 To clucth cover. 11. Install: 9 Clutch cover 1 9 Bolt (clutch cover) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 12.
• Page 291
  EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO 10. Monter: 10. Installare: 10. Einbauen: 9 Joint torique 1 9 Anello di tenuta 1 9 O-Ring 1 Vers le couvercle d’embrayage. Verso la protezione della frizio- Zum Kupplungsdeckel.

• Page 292: Kick Axle, Shift Shaft And Primary Drive Gear

  KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C0000 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8000 PRIMARY DRIVE GEAR 30 Nm (3.0 m•kg, 22 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) 1 Primary drive gear removal Extent of removal: Extent of removal Order…

• Page 293
  AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE PIGNON DE TRANSMISSION PRIMAIRE 1 Dépose du pignon de transmission primaire Etendue de dépose: Etendue de dépose…

• Page 294: Kick Axle And Shift Shaft

  KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8100 KICK AXLE AND SHIFT SHAFT 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Kick axle and kick idle gear removal Extent of removal: 2 Shift shaft and stopper lever removal Extent of removal…

• Page 295
  AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR 1 Dépose de l’axe de démarreur au pied et du pignon de renvoi de démarreur au pied Etendue de dépose: 2 Dépose de l’arbre de sélecteur et du levier de butée Etendue de dépose…
• Page 296
  KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C3000 REMOVAL POINTS EC483111 Primary drive gear 1. Loosen: 9 Bolt (primary drive gear) 1 NOTE: Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3. EC4B3101 Kick axle assembly 1.
• Page 297
  AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4C3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC483111 Ingranaggio conduttore primario Pignon de transmission primaire Primärantriebszahnrad 1.
• Page 298
  KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C4300 Kick gear, kick idle gear and ratchet wheel 1. Inspect: 9 Kick gear 1 9 Kick idle gear 2 9 Ratchet wheel 3 9 Gear teeth a 9 Ratchet teeth b Wear/Damage ¡…
• Page 299
  AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4C4300 Pignon de démarreur au pied, pignon Ingranaggio della pedivella ingranag- Kickstarterzahnrad, Kickstarter- gio folle della pedivella e ruota a cric- de renvoi de démarreur au pied et Zwischenzahnrad und Sperrad roue à…
• Page 300
  KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C5000 ASSEMBLY AND INSTALLATION EC4C5130 Stopper lever 1. Install: 9 Tension spring 1 9 Holder 2 9 Bolt (holder) 3 10 Nm (1.0 m•kg, 7.2 ft•lb) 9 Plain washer 4 9 Stopper lever 5 9 Bolt (stopper lever) 6 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE:…
• Page 301
  AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4C5000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E INSTALLAZIONE MONTAGE IC4C5130 Leva di fermo Levier de butée Anschlaghebel 1.
• Page 302
  KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 4. Install: 9 Bolt (shift guide) 1 10 Nm (1.0 m•kg, 7.2 ft•lb) EC4C5310 Shift shaft 1. Install: 9 Roller 1 9 Plain washer 2 9 Shift shaft 3 NOTE: Apply the transmission oil on the roller and shift shaft.
• Page 303
  AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO 4. Monter: 4. Installare: 4. Einbauen: 9 Boulon (guide de sélecteur) 1 9 Bullone (guida del cambio) 1 9 Schraube (Schaltführung) 1 10 Nm (1,0 m•kg, 7,2 ft•lb) 10 Nm (1,0 m•kg, 7,2 ft•lb)
• Page 304
  KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 3. Install: 9 Spring guide 1 NOTE: Slide the spring guide into the kick axle, make sure the groove a in the spring guide fits on the stopper of the torsion spring. 4.
• Page 305
  AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO 3. Monter: 3. Installare: 3. Einbauen: 9 Guide de ressort 1 9 Guida della molla 1 9 Federführung 1 N.B.: HINWEIS:…
• Page 306
  KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C5531 Primary drive gear 1. Install: 9 Thrust plate 1 9 Primary drive gear 2 9 Governor drive gear 3 9 Plain washer 4 9 Bolt (primary drive gear) 5 NOTE: 9 Install the plain washer with its chamfered side a toward you.
• Page 307
  AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4C5531 Ingranaggio conduttore primario Pignon de transmission primaire Primärantriebszahnrad 1. Installare: 1. Monter: 1. Einbauen: 9 Plaque de butée 1 9 Disco di spinta 1 9 Druckscheibe 1…
• Page 308
  KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 6. Install: 9 Bolt [crankcase cover (right)] 1 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 7. Install: 9 Kick starter 1 9 Plain washer 2 9 Bolt (kick starter) 3 30 Nm (3.0 m•kg, 22 ft•lb) NOTE:…
• Page 309
  AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE 6. Monter: 6. Installare: 6. Einbauen: 9 Boulon [couvercle de carter 9 Bullone [copertura del carter 9 Schraube (destra)] 1 (droit)]1…

• Page 310: Ypvs Governor

  YPVS GOVERNOR EC4K0000 YPVS GOVERNOR 5 Nm (0.5 m•kg, 3.6 ft•lb) 1 YPVS governor removal and disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks YPVS GOVERNOR REMOVAL Preparation for Crankcase cover (right) Refer to “KICK AXLE, SHIFT SHAFT AND removal PRIMARY DRIVE GEAR”…

• Page 311: Regulateur Ypvs

  REGULATEUR YPVS YPVS REGLER REGOLATORE YPVS REGULATEUR YPVS 1 Dépose et démontage du régulateur YPVS Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU REGULATEUR YPVS Préparation pour la dépose Couvercle de carter (droit) Se reporter à la section “AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION”.

• Page 312
  YPVS GOVERNOR EC4K3000 REMOVAL POINTS EC4K3100 Governor 1. Remove: 9 Dowel pin 1 NOTE: While compressing the spring, remove the dowel pin. EC4K4000 INSPECTION EC4K4100 Governor groove 1. Inspect: 9 Plain washer 1 9 Collar 2 Wear/Damage ¡ Replace. EC4K4200 Bearing 1.
• Page 313
  REGULATEUR YPVS YPVS REGLER REGOLATORE YPVS IC4K3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC4K3100 Régulateur Regler Regolatore 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Goujon 1 9 Paßstift 1 9 Perno di riferimento 1 N.B.: HINWEIS: NOTA: Déposer le goujon tout en comprimant Die Feder zusammendrüken, und den Togliere il perno di riferimento compri- le ressort.
• Page 314
  YPVS GOVERNOR 2. Install: 9 Ball 1 9 Retainer 2 To governor shaft 3. NOTE: Apply the transmission oil on the retainer and ball. 3. Install: 9 Dowel pin 1 NOTE: 9 While compressing the spring, install the dowel pin. 9 Make sure the dowel pin fits into the groove a in the retainer.
• Page 315
  POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA 2. Monter: 2. Installare: 2. Einbauen: 9 Bille 1 9 Sfera 1 9 Kugel 1 9 Retenue 2 9 Fermo 2 9 Halter 2 sur l’arbre du régulateur 3. Sull’albero del regolatore 3. Zur Reglerachse 3. N.B.: HINWEIS: NOTA:…

• Page 316: Water Pump

  WATER PUMP EC4G0000 WATER PUMP 10 Nm (1.0 m•kg, 7.2 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Impeller shaft removal 2 Oil seal removal Extent of removal: Extent of removal Order Part name Q’ty Remarks WATER PUMP DISASSEMBLY…

• Page 317: Pompe A Eau

  POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA POMPE A EAU 1 Dépose du pignon d’axe de turbine 2 Dépose de bague d’étanchéité Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA POMPE A EAU Préparation pour la dépose Couvercle de carter (droit) Se reporter à…

• Page 318
  WATER PUMP EC4G3000 REMOVAL POINTS EC4G3110 Impeller shaft 1. Remove: 9 Impeller 1 9 Plain washer 2 9 Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller. EC4G3210 Oil seal NOTE:…
• Page 319
  POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA IC4G3000 POINTS DE DEPOSE PUNTI DI RIMOZIONE AUSBAUPUNKTE IC4G3110 Axe de turbine Flügelradwelle Albero del girante 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Turbine 1 9 Flügelrad 1 9 Girante 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 9 Axe de turbine 3…
• Page 320
  WATER PUMP EC444300 Impeller shaft gear 1. Inspect: 9 Gear teeth a Wear/Damage ¡ Replace. EC4H4600 Bearing 1. Inspect: 9 Bearing 1 Rotate inner race with a finger. Rough spot/Seizure ¡ Replace. EC444400 Oil seal 1. Inspect: 9 Oil seal 1 Wear/Damage ¡…
• Page 321
  POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA IC444300 Pignon d’axe de turbine Ingranaggio dell’albero del girante Flügelradwellenzahnrad 1. Examiner: 1. Ispezionare: 1. Prüfen: 9 Dents a 9 Denti dell’ingranaggio a 9 Zähne a Usure/endommagement¡ Usura/Danni¡Sostituirli. Abnutzung/Beschädigung¡ Changer. Erneuern. IC4H4600 Cuscinetto Roulement Lager 1.
• Page 322
  WATER PUMP EC4G5220 Impeller shaft 1. Install: 9 Impeller shaft 1 NOTE: 9 Take care so that the oil seal lip is not dam- aged or the spring does not slip off its position. 9 When installing the impeller shaft, apply the lithium soap base grease on the oil seal lip and impeller shaft.
• Page 323
  MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI IC4G5220 Axe de turbine Flügelradwelle Albero del girante 1. Monter: 1. Einbauen: 1. Installare: 9 Axe de turbine 1 9 Flügelradwelle 1 9 Albero del girante 1 N.B.: HINWEIS: NOTA: 9 Prendre garde à ne pas endommager 9 Darauf achten, daß…

• Page 324: Cdi Magneto

  CDI MAGNETO EC4L0000 CDI MAGNETO 8 Nm (0.8 m•kg, 5.8 ft•lb) 8 Nm (0.8 m•kg, 5.8 ft•lb) 56 Nm (5.6 m•kg, 40 ft•lb) 1 CDI magneto removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CDI MAGNETO REMOVAL Preparation for Seat and fuel tank Refer to “SEAT, FUEL TANK AND…

• Page 325: Magneto Cdi

  MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI MAGNETO CDI 1 Dépose de la magnéto CDI Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA MAGNETO CDI Préparation pour la dépose Selle et réservoir à essence Se reporter à la section “SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX”.

• Page 326
  CDI MAGNETO EC4L3000 REMOVAL POINTS EC4L3102 Rotor 1. Remove: 9 Nut (rotor) 1 9 Plain washer 2 Use the rotor holding tool 3. Rotor holding tool: YU-1235/90890-01235 2. Remove: 9 Rotor 1 Use the flywheel puller 2. Flywheel puller: YM-1189/90890-01189 NOTE: When installing the flywheel puller, turn it coun- terclockwise.
• Page 327
  MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI IC4L3000 POINTS DE DEPOSE PUNTI DI RIMOZIONE AUSBAUPUNKTE IC4L3102 Rotor Rotor Rotore 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Ecrou (rotor) 1 9 Mutter (Rotor) 1 9 Dado (rotore) 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 Den Rotor-Haltewerkzeug 3 Utiliser l’outil de poignée de…
• Page 328
  CDI MAGNETO 2. Install: 9 Woodruff key 1 9 Rotor 2 NOTE: 9 Clean the tapered portions of the crankshaft and rotor. 9 When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b.
• Page 329
  MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI 2. Monter: 2. Installare: 2. Einbauen: 9 Clavette de demi-lune 1 9 Linguetta Woodruff 1 9 Einlegekeil 1 9 Rotor 2 9 Rotore 2 9 Rotor 2 N.B.: HINWEIS: NOTA: 9 Nettoyer la paritie conique de l’extré- 9 Pulire le parti coniche dell’albero a 9 Den Kegeligen Teil des Kurbelwel- mité…
• Page 330
  CDI MAGNETO 7. Connect: 9 CDI magneto lead 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 8. Install: 9 Gasket [crankcase cover (left)] 9 Crankcase cover (left) 1 9 Screw [crankcase cover (left)] 2 8 Nm (0.8 m•kg, 5.8 ft•lb) NOTE: Tighten the screws in stage, using a crisscross pattern.
• Page 331
  MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI 7. Connecter: 7. Collegare: 7. Anschließen: 9 Fil de magnéto CDI 1 9 Conduttore del magnete CDI 1 9 Kabel des CDI-Magnetzünders Se référer au paragraphe “DIA- Consultare la sezione “DIA- GRAMME CHEMINE- GRAMMA DEL PASSAGGIO Siehe Abschnitt „KABELFÜH- MENT DE CABLE”…

• Page 332: Engine Removal

  ENGINE REMOVAL EC4M0000 ENGINE REMOVAL 85 Nm (8.5 m•kg, 61 ft•lb) 34 Nm (3.4 m•kg, 24 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 75 Nm (7.5 m•kg, 54 ft•lb) 8 Nm (0.8 m•kg, 5.8 ft•lb) Extent of removal Order…

• Page 333: Depose Du Moteur

  DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE DEPOSE DU MOTEUR Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU MOTEUR Préparation pour la dépose Maintenir la machine en plaçant un Bien soutenir la la machine afin qu’elle ne risque support approprié…

• Page 334
  ENGINE REMOVAL 85 Nm (8.5 m•kg, 61 ft•lb) 34 Nm (3.4 m•kg, 24 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 75 Nm (7.5 m•kg, 54 ft•lb) 8 Nm (0.8 m•kg, 5.8 ft•lb) 1 Engine removal Extent of removal: Extent of removal…

• Page 335: Rimozione Del Motore

  DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE 1 Dépose du moteur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques Couvercle de chaîne  Ecrou (pignon d’entraînement)  Rondelle-frein  Se reporter à “POINTS DE DEPOSE”. …

• Page 336
  ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: 9 Nut (drive sprocket) 1 9 Lock washer 2 NOTE: 9 Straighten the lock washer tab. 9 Loosen the nut while applying the rear brake. 2. Remove: 9 Drive sprocket 1 9 Drive chain 2 NOTE: Remove the drive sprocket together with the…
• Page 337
  DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE IC4M3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC4F3100 Pignon d’entraînement Antriebskettenrad Rocchetto conduttore 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Ecrou (pignon d’entraînement) 1 9 Mutter (Antriebskettenrad) 1 9 Dado (rocchetto conduttore) 1 9 Rondelle-frein 2 9 Sicherungsscheibe 2 9 Rosetta di sicurezza 2…
• Page 338
  ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION EC4M5124 Engine installation 1. Install: 9 Engine 1 Install the engine from right side. 9 Pivot shaft 2 85 Nm (8.5 m•kg, 61 ft•lb) 9 Engine mounting bolt (lower) 3 69 Nm (6.9 m•kg, 50 ft•lb) 9 Engine mounting bolt (front) 4 69 Nm (6.9 m•kg, 50 ft•lb) 9 Engine bracket 5…
• Page 339
  DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE IC4M5000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E MONTAGE INSTALLAZIONE IC4M5124 Montage du moteur Einbau des Motors Installazione del motore 1. Monter: 1. Einbauen: 1. Installare: 9 Moteur 1 9 Motor 1 9 Motore 1 Monter le moteur par le côté…
• Page 340
  ENGINE REMOVAL EC4M5341 Drive sprocket 1. Install: 9 Drive sprocket 1 9 Drive chain 2 NOTE: Install the drive sprocket together with the drive chain. 2. Install: 9 Lock washer 1 9 Nut (drive sprocket) 2 75 Nm (7.5 m•kg, 54 ft•lb) NOTE: Tighten the nut while applying the rear brake.
• Page 341
  DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE Pignon d’entraînement IC4M5341 Antriebskettenrad Rocchetto conduttore 1. Monter: 1. Einbauen: 1. Installare: 9 Pignon d’entraînement 1 9 Antriebskettenrad 1 9 Rocchetto conduttore 1 9 Chaîne de transmission 2 9 Antriebskette 2 9 Catena di trasmissione 2 N.B.: HINWEIS:…

• Page 342: Crankcase And Crankshaft

  CRANKCASE AND CRANKSHAFT EC4N0000 CRANKCASE AND CRANKSHAFT 10 Nm (1.0 m•kg, 7.2 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Crankcase separation 2 Crankshaft removal Extent of removal: 3 Crankshaft bearing removal Extent of removal Order…

• Page 343: Carter Et Vilebrequin

  CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI CARTER ET VILEBREQUIN 1 Séparation du carter 2 Dépose du vilebrequin Etendue de dépose: 3 Dépose du roulement de vilebrequin Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU CARTER ET DU VILEBREQUIN Préparation pour la dépose…

• Page 344
  CRANKCASE AND CRANKSHAFT EC4N3000 REMOVAL POINTS EC4N3100 Segment 1. Remove: 9 Bolt (segment) 1 9 Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt. EC4N3212 Crankcase 1. Remove: 9 Crankcase (right) 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 NOTE:…
• Page 345
  CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC4N3100 Segment Segment Segmento 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Boulon (segment) 1 9 Schraube (Segment) 1 9 Bullone (segmento) 1 9 Segment 2 9 Segment 2 9 Segmento 2…
• Page 346
  CRANKCASE AND CRANKSHAFT EC4N3302 Crankshaft 1. Remove: 9 Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 NOTE: Make appropriate bolts 3 as shown available by yourself and attach the tool with them. Do not use a hammer to drive out the crankshaft.
• Page 347
  CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N3302 Vilebrequin Albero a gomiti Kurbelwelle 1. Déposer: 1. Togliere: 1. Ausbauen: 9 Vilebrequin 1 9 Albero a gomiti 1 9 Kurbelwelle 1 Utilisez le séparateur de carter Usare l’utensile per separare il Kurbelgehäuse-Trennwerkzeug carter 2.
• Page 348
  CRANKCASE AND CRANKSHAFT 2. Inspect: 9 Bearings 1 Rotate inner race with a finger. Rough spot/Seizure ¡ Replace. 3. Inspect: 9 Oil seal 1 Damage ¡ Replace. EC4N4202 Crankshaft 1. Measure: 9 Runout limit a 9 Small end free play limit b 9 Connecting rod big end side clearance c 9 Crank width d Out of specification ¡…
• Page 349
  CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI 2. Examiner: 2. Ispezionare: 2. Prüfen: 9 Roulements 1 9 Cuscinetti 1 9 Lager 1 Faire tourner la bague intérieure Ruotare l’anello interno con un inneren Laufring avec le doigt. dito.
• Page 350
  CRANKCASE AND CRANKSHAFT EC4N5102 Oil seal 1. Install: 9 Oil seal (left) 1 9 Oil seal (right) 2 NOTE: 9 Apply the lithium soap base grease on the oil seal lip. 9 Install the oil seal with its manufacture’s marks or numbers facing outward.
• Page 351
  CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N5102 Bague d’étanchéité Paraolio Öldichtung 1. Monter: 1. Installare: 1. Einbauen: 9 Bague d’étanchéité (gauche) 1 9 Paraolio (sinistro) 1 9 Öldichtung (Links) 1 9 Paraolio (destro) 2 9 Öldichtung (Rechts) 2 9 Bague d’étanchéité…
• Page 352
  To crankcase (right) 2. 4. Apply: 9 Sealant On the crankcase (right) 1. ® Quick gasket ACC-QUICK-GS-KT Yamaha bond No. 1215: 90890-85505 NOTE: Clean the contacting surface of crankcase (left and right) before applying the sealant. 5. Install: 9 Dowel pin 1 9 Crankcase (right) 2 To crankcase (left) 3.
• Page 353
  Sul carter (destro) 1. Kurbelgehäuse (Rechts) 1. Quick Gasket Quick Gasket ® ® ACC-QUICK-GS-KT ACC-QUICK-GS-KT Quick Gasket ® Legante Yamaha No. 1215: Yamaha Bond N°1215: ACC-QUICK-GS-KT 90890-85505 90890-85505 Yamaha Bond Nr. 1215: 90890-85505 N.B.: NOTA: HINWEIS: Nettoyer la surface de contact des…
• Page 354
  CRANKCASE AND CRANKSHAFT 7. Install: 9 Tension spring 1 9 Holder 2 9 Bolt (holder) 3 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Install the holder so that it contacts the projec- tion a on the crankcase (right). 8. Tighten: 9 Segment 1 9 Bolt (segment) 2 30 Nm (3.0 m•kg, 22 ft•lb)
• Page 355
  CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI 7. Monter: 7. Installare: 7. Einbauen: 9 Ressort de tension 1 9 Molla di tensione 1 9 Zugfeder 1 9 Support 2 9 Supporto 2 9 Halter 2 9 Boulon (support) 3 9 Bullone (supporto) 3 9 Schraube (Halter) 3 10 Nm (1,0 m•kg, 7,2 ft•lb)

• Page 356: Transmission, Shift Cam And Shift Fork

  TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK 1 Main axle, drive axle, shift cam and shift fork removal Extent of removal: Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Preparation for Engine Refer to “ENGINE REMOVAL”…

• Page 357
  BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE 1 Dépose de l’arbre principal, de l’arbre d’entraînement, du barillet du sélecteur et de la fourchette du sélecteur. Etendue de dépose: Etendue de dépose Ordre…
• Page 358
  TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1. Remove: 9 Main axle 1 9 Drive axle 2 9 Shift cam 9 Shift fork 3 9 Shift fork 2 9 Shift fork 1 NOTE: 9 Remove assembly carefully. Note the position of each part.
• Page 359
  BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO IC4H3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC4H3230 Boîte à vitesses Getribe Trasmissione 1. Déposer: 1. Togliere: 1. Ausbauen: 9 Axe principal 1 9 Asse principale 1 9 Hauptwelle 1…
• Page 360
  TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4810 Shift fork, shift cam and segment 1. Inspect: 9 Shift fork 1 Wear/Damage/Scratches ¡ Replace. 2. Inspect: 9 Shift cam 1 9 Segment 2 Wear/Damage ¡ Replace. 3. Check: 9 Shift fork movement Unsmooth operation ¡…
• Page 361
  BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO IC4H4810 Fourchette, barillet de sélecteur et Forcella del cambio, camma del cam- Schaltgabel, Schaltnocke und Segment bio e segmento segment 1.
• Page 362
  TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: 9 2nd wheel gear (23 T) 1 9 4th wheel gear (24 T) 2 9 3rd wheel gear (23 T) 3 9 5th wheel gear (20 T) 4 9 1st wheel gear (27 T) 5 9 O-ring 6 To drive axle 7.
• Page 363
  BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO 2. Monter: 2. Installare: 2. Einbauen: 9 2e engranage de pignon (23D) 1 9 Ingranaggio a ruota 2 (23T) 1 Zahnrad für 2.
• Page 364
  TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: 9 Shift fork 1 (L) 1 9 Shift fork 2 (C10) 2 9 Shift fork 3 (R) 3 9 Shift cam 4 To main axle and drive axle. NOTE: 9 Apply the molybdenum disulfide oil on the shift fork grooves.
• Page 365
  BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO 5. Monter: 5. Installare: 5. Einbauen: 9 Fourchette 1 (L) 1 9 Forcella del cambio 1 (L) 1 Schaltgabel 1 (L) 1 9 Fourchette 2 (C10) 2 9 Forcella del cambio 2 (C10) 2 Schaltgabel 2 (C10) 2…

• Page 366: Front Wheel

  CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 23 Nm (2.3 m•kg, 17 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 105 Nm (10.5 m•kg, 75 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb)

• Page 367: Partie Cycle

  ROUE AVANT ET ROUE ARRIEREF VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE ROUE AVANT 1 Dépose de la roue avant 2 Dépose du roulement de roue 3 Dépose du disque de frein Etendue de dépose: Etendue de dépose Ordre…

• Page 368: Rear Wheel

  CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL 14 Nm (1.4 m•kg, 10 ft•lb) 125 Nm (12.5 m•kg, 90 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 42 Nm (4.2 m•kg, 30 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal:…

• Page 369: Ruota Anteriore E Ruota Posteriore

  ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE ROUE ARRIERE 1 Dépose de roue arrière 2 Dépose du roulement de roue 3 Dépose du disque de frein Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té…

• Page 370
  CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: 9 Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: 9 Bearing 1 NOTE: Remove the bearing using a general bearing puller 2.
• Page 371
  ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE IC593000 PUNTI DI RIMOZIONE POINTS DE DEPOSE AUSBAUPUNKTE Roue arrière Hinterrad IC523101 Ruota posteriore 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Roue 1 9 Rad 1 9 Ruota 1 N.B.: HINWEIS:…
• Page 372
  CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: 9 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 373
  ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE IC514200 Axe de roue Radachse Asse della ruota 1. Mesurer: 1. Messen: 1. Misurare: 9 Les flexions de l’axe de roue 9 Radachsenbiegung 9 Curvature dell’asse della ruota Hors-spécification ¡…
• Page 374
  CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION EC595101 Front wheel 1. Install: 9 Bearing (left) 1 9 Spacer 2 9 Bearing (right) 3 9 Oil seal 4 NOTE: 9 Apply the lithium soap base grease on the bearing and oil seal lip when installing.
• Page 375
  ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE IC595000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E Vorderrad MONTAGE INSTALLAZIONE 1. Einbauen: Roue avant IC595101 9 Lager (Links) 1 1. Monter: Ruota anteriore 9 Distanzhülse 2 9 Roulement (gauche) 1 1.

• Page 376: Front Fork

  CHAS FRONT WHEEL AND REAR WHEEL 5. Install: 9 Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. 6. Install: 9 Nut (wheel axle) 1 105 Nm (10.5 m•kg, 75 ft•lb) 7. Tighten: 9 Bolt (axle holder) 1 23 Nm (2.3 m•kg, 17 ft•lb) NOTE: Before tightening the bolt, fit the wheel axle to…

• Page 377
  ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 5. Monter: 5. Installare: 5. Einbauen: 9 Axe de roue 1 9 Asse della ruota 1 9 Radachse 1 N.B.: HINWEIS: NOTA: Appliquer de la graisse à base de savon Applicare sull’asse della ruota il grasso Das Lithiumfett auf Radachse auftra- au lithium sur l’axe de roue.
• Page 378
  CHAS FRONT WHEEL AND REAR WHEEL 9. Install: 9 Hose cover 1 9 Plain washer 2 9 Bolt [hose cover (M8)] 3 16 Nm (1.6 m•kg, 11 ft•lb) 9 Bolt [hose cover (M6)] 4 7 Nm (0.7 m•kg, 5.1 ft•lb) EC5251A1 Rear wheel 1.
• Page 379
  ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 9. Monter: 9. Installare: 9. Einbauen: 9 Couvercle de tuyau 1 9 Copertura del tubo flessibile 1 9 Schlauchdeckel 1 9 Rondelle ordinaire 2 9 Rosetta 2 9 Beilegescheibe 2 9 Boulon 9 Bullone [copertura del tubo fles-…
• Page 380
  CHAS FRONT WHEEL AND REAR WHEEL 3. Install: 9 Driven sprocket 1 9 Bolt (driven sprocket) 2 9 Plain washer (driven sprocket) 3 9 Nut (driven sprocket) 4 42 Nm (4.2 m•kg, 30 ft•lb) NOTE: Tighten the nuts in stage, using a crisscross pat- tern.
• Page 381
  ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 3. Monter: 3. Installare: 3. Einbauen: 9 Pignon mené 1 9 Rocchetto condotto 1 9 Abtriebskettenrad 1 9 Boulon (pignon mené) 2 9 Bullone (rocchetto condotto) 2 9 Schraube (Abtriebskettenrad) 9 Rondelle…
• Page 382
  CHAS FRONT WHEEL AND REAR WHEEL 8. Install: 9 Chain puller (right) 1 9 Plain washer 2 9 Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point. 9. Adjust: 9 Drive chain slack a Drive chain slack : 40~50 mm (1.6~2.0 in) Refer to “DRIVE CHAIN SLACK ADJUSTMENT”…
• Page 383
  ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 8. Monter: 8. Installare: 8. Einbauen: 9 Tendeur de chaîne (droit) 1 9 Estrattore per catena (destro) 1 9 Kettenspanner (Rechts) 1 9 Rondelle ordinaire 2 9 Rosetta 2 9 Beilegescheibe 2 9 Ecrou (axe de roue) 3…

• Page 384: Front Brake

  CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 9 Nm (0.9 m•kg, 6.5 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb)

• Page 385: Frein Avant Et Frein Arriere

  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE FREIN AVANT ET FREIN ARRIERE FREIN AVANT 1 Dépose du tuyau de frein 2 Dépose de l’étrier 3 Dépose du maître-cylindre Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té…

• Page 386: Rear Brake

  CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE 30 Nm (3.0 m•kg, 22 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb)

• Page 387: Freno Posteriore

  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE FREIN ARRIERE 1 Dépose du maître-cylindre 2 Dépose du tuyau de frein 3 Dépose de l’étrier Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té…

• Page 388: Caliper Disassembly

  CHAS FRONT BRAKE AND REAR BRAKE EC5A8200 CALIPER DISASSEMBLY 18 Nm (1.8 m•kg, 13 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) A Front B Rear 1 Front caliper disassembly…

• Page 389
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE DEMONTAGE DE L’ETRIER A Avant B Arrière 1 Démontage de l’étrier avant 2 Démontage de l’étrier arrière Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té…
• Page 390
  CHAS FRONT BRAKE AND REAR BRAKE EC5A8300 MASTER CYLINDER DISASSEMBLY å 2 Nm (0.2 m•kg, 1.4 ft•lb) 2 Nm (0.2 m•kg, 1.4 ft•lb) ∫ A Front B Rear 1 Front master cylinder disassembly 2 Rear master cylinder disassembly Extent of removal: Extent of removal Order Part name…
• Page 391
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE DEMONTAGE DU MAITRE-CYLINDRE A Avant B Arrière 1 Démontage du maître-cylindre avant 2 Démontage du maître-cylindre arrière Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té…
• Page 392
  CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 REMOVAL POINTS EC5A3101 Brake fluid 1. Remove: [Front] 9 Master cylinder cap 1 [Rear] 9 Master cylinder cap 1 9 Protector NOTE: Do not remove the diaphragm. A Front B Rear 2. Connect the transparent hose 1 to the bleed screw 2 and place a suitable contain- er under its end.
• Page 393
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE IC5A3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE Liquide de frein Bremsflüssigkeit IC5A3101 1. Déposer: 1. Ausbauen: Liquido per freni [Avant] [Vorne] 1. Togliere: 9 Coupelle du maître-cylindre 1 9 Hauptbremszylinderkappe 1 [Anteriormente] [Arrière]…
• Page 394
  CHAS FRONT BRAKE AND REAR BRAKE EC533402 Piston seal kit 1. Remove: 9 Dust seal 1 9 Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. Never attempt to pry out piston seals and dust seals.
• Page 395
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE IC533402 Kit de joint de piston Kolbendichtungseinsatz Kit delle guarnizioni di tenuta del 1. Déposer: pistone 1. Ausbauen: 9 Joint antipoussière 1 9 Staubdichtung 1 1. Togliere: 9 Joint de piston 2 9 Parapolvere 1 9 Kolbendichtung 2…
• Page 396
  CHAS FRONT BRAKE AND REAR BRAKE EC534214 Caliper 1. Inspect: 9 Caliper cylinder inner surface a Wear/Score marks¡Replace caliper as- sembly. A Front B Rear 2. Inspect: 9 Caliper piston 1 Wear/Score marks¡Replace caliper piston assembly. Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled.
• Page 397
  FREAIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE IC534214 Etrier Bremssattel Pinza 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Surface 9 Inneren Oberfläche des Haupt- interne maître- 9 Superficie interna del cilindro cylindre a bremszylinders a della pinza a U s u r e / r a y u r e s ¡…
• Page 398
  CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9 Piston seal 1 9 Dust seal 2 Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. A Front B Rear 3.
• Page 399
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Installare: 2. Einbauen: 9 Joint de piston 1 9 Guarnizione di tenuta del pisto- 9 Kolbendichtung 1 9 Joint antipoussière 2 ne 1 9 Staubdichtung 2 9 Parapolvere 2 Toujours utiliser des joints de piston…
• Page 400
  CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9 Copper washer 1 9 Union bolt 2 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers. Install the brake hose so that its pipe por- tion a a directs as shown and lightly touch- es the projection b b on the caliper.
• Page 401
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Installare: 2. Einbauen: 9 Rondelle en cuivre 1 9 Rondella in rame 1 9 Kupferscheibe 1 9 Boulon d’union 2 9 Bullone di unione 2 9 Unionschraube 2 30 Nm (3,0 m•kg, 22 ft•lb) 30 Nm (3,0 m•kg, 22 ft•lb)
• Page 402
  CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9 Disc cover 1 9 Bolt (disc cover) 2 7 Nm (0.7 m•kg, 5.1 ft•lb) 3. Install: 9 Caliper 1 9 Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section. 4.
• Page 403
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Installare: 2. Einbauen: 9 Couvercle de disque 1 9 Copridisco 1 9 Scheibendeckel 1 9 Boulon (couvercle de disque) 2 9 Bullone (copridisco) 2 9 Schraube (Scheibendeckel) 2 7 Nm (0,7 m•kg, 5,1 ft•lb) 7 Nm (0,7 m•kg, 5,1 ft•lb)
• Page 404
  CHAS FRONT BRAKE AND REAR BRAKE 3. Install: 9 Spring 1 To master cylinder piston 2. NOTE: Install the spring at the smaller dia. side. A Front B Rear 4. Install: [Front] 9 Master cylinder kit 1 9 Plain washer 2 9 Circlip 3 9 Master cylinder boot 4 To master cylinder 5.
• Page 405
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 3. Monter: 3. Installare: 3. Einbauen: 9 Ressort 1 9 Molla 1 9 Feder 1 Au piston de maître-cylindre 2. Sul pistone del cilindro princi- Hauptbremszylinderkol- pale 2.
• Page 406
  CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9 Brake lever 1 9 Bolt (brake lever) 2 6 Nm (0.6 m•kg, 4.3 ft•lb) 9 Nut (brake lever) 3 6 Nm (0.6 m•kg, 4.3 ft•lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston.
• Page 407
  FREIN AVNAT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Installare: 2. Einbauen: 9 Levier de frein 1 9 Leva di comando del freno 1 9 Bremshebel 1 9 Boulon (levier de frein) 2 9 Bullone (leva di comando del 9 Schraube (Bremshebel) 2 freno) 2…
• Page 408
  CHAS FRONT BRAKE AND REAR BRAKE 3. Install: 9 Spring 1 9 Brake pedal 2 9 O-ring 3 9 Bolt (brake pedal) 4 26 Nm (2.6 m•kg, 19 ft•lb) 9 Clip 5 NOTE: 9 Apply the lithium soap base grease on the bolt, O-ring and brake pedal bracket.
• Page 409
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 3. Monter: 3. Installare: 3. Einbauen: 9 Ressort 1 9 Molla 1 9 Feder 1 9 Pédale de frein 2 9 Pedale di comando del freno 2 9 Bremspedal 2 9 Joint torique 3 9 Anello di tenuta 3…
• Page 410
  CHAS FRONT BRAKE AND REAR BRAKE 3. Pass the brake hose through the cable guide 1, then through the guide a on the protector 2. 4. Install: 9 Copper washer 1 9 Brake hose 2 9 Union bolt 3 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers.
• Page 411
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE AND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 3. Faire passer la tuyau de frein dans 3. Far passare il tubo flessibile del 3. Den Bremsschlauch durch die le guide de câble 1, puis dans le Kabelführung 1 und danach freno attraverso la guida per cavi guide a sur le protecteur 2.
• Page 412
  CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9 Brake hose holder 1 9 Screw (brake hose holder) 2 1 Nm (0.1 m•kg, 0.7 ft•lb) After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist.
• Page 413
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Installare: 2. Einbauen: 9 Support de tuyau de frein 1 9 Supporto del tubo flessibile del 9 Bremsschlauchhalter 1 9 Vis (support de tuyau de frein) 2 freno 1 9 Schraube (Bremsschlauchhal- 9 Vite (supporto del tubo flessibi-…
• Page 414
  CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: 9 Brake system Refer to “BRAKE SYSTEM AIR BLEED- ING” section in the CHAPTER 3. 3. Inspect: 9 Brake fluid level Fluid at lower level¡Fill up. Refer to “BRAKE FLUID LEVEL INSPEC- TION”…
• Page 415
  FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Purger de l’air: 2. Spurgo dell’aria: 2. Entlüften: 9 Système de freinage 9 Impianto frenante 9 Bremsanlage Se reporter à la section “PRISE Consultare la sezione “SPUR- Siehe Abschnitt „ENTLÜFTEN D’AIR DU SYSTEME DE GO DELL’ARIA DAL SISTE-…
• Page 416
  CHAS FRONT FORK EC550000 FRONT FORK 4 Nm (0.4 m•kg, 2.9 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Front fork removal Extent of removal: Extent of removal…

• Page 417: Fourche Avant

  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE FOURCHE AVANT 1 Dépose de la fourche avant Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA FOURCHE AVANT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas approprié…

• Page 418: Front Fork Disassembly

  CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY 1 Nm (0.1 m•kg, 0.7 ft•lb) 29 Nm (2.9 m•kg, 21 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) 1 Oil seal removal 2 Damper rod removal Extent of removal: Extent of removal Order Part name…

• Page 419: Forcella Anteriore

  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE DEMONTAGE DE LA FOURCHE AVANT 1 Dépose de la bague d’étanchéité 2 Dépose de la tige d’amortisseur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEMONTAGE DE LA FOURCHE AVANT Boulon capuchon Se reporter à…

• Page 420
  CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. To prevent an accidental explosion of air, the following instructions should be ob- served: 9 The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to…
• Page 421
  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC556000 REMARQUES HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO CONCERNANT LA HINWEIS: NOTA: MANIPULATION Die Vorderradgabel erfordert beson- La forcella anteriore richiede grande at- dere Aufmerksamkeit. Daher wird N.B.: tenzione. Si raccomanda pertanto di ef- empfohlen, Wartungsarbeiten an der fettuare la manutenzione della forcella La fourche avant nécessite une soigneu- Vorderradgebel…
• Page 422
  CHAS FRONT FORK EC553201 Inner tube 1. Remove: 9 Dust seal 1 9 Stopper ring 2 Using slotted-head screwdriver. Take care not to scratch the inner tube. 2. Remove: 9 Inner tube 1 Oil seal removal steps: 9 Push in slowly a the inner tube just be- fore it bottoms out and then pull it back quickly b.
• Page 423
  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC553201 Tube interne Innere Rohr Tubo interno 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Joint antipoussière 1 9 Staubdichtung 1 9 Parapolvere 1 9 Bague d’arrêt 2 9 Anschlagring 2 9 Anello di fermo 2 En utilisant un tournevis à…
• Page 424
  CHAS FRONT FORK EC554200 Base valve 1. Inspect: 9 Valve assembly 1 Wear/Damage¡Replace. 9 O-ring 2 Damage¡Replace. EC554400 Fork spring 1. Measure: 9 Fork spring free length a Out of specification¡Replace. Fork spring free length: Standard <Limit> 460 mm 455 mm (18.1 in) (17.9 in) EC554502…
• Page 425
  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC554200 Soupare de base Valvola di base Hauptventil 1. Examiner: 1. Ispezionare: 1. Prüfen: 9 Ensemble clapet 1 9 Gruppo valvola 1 9 Ventileinheit 1 Usure/endommagement Usura/Danni¡Sostituirlo. Abnutzung/Beschädigung ¡Changer. ¡Erneuern. 9 Anello di tenuta 2 9 Joint torique 2 9 O-Ring 2 Danni¡Sostituirlo.
• Page 426
  CHAS FRONT FORK EC554700 Cap bolt 1. Inspect: 9 Cap bolt 1 9 O-ring 2 9 Air bleed screw 3 Wear/Damage¡Replace. EC555000 ASSEMBLY AND INSTALLATION EC5551A1 Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: 9 Damper rod 1 To inner tube 2.
• Page 427
  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC554700 Boulon capuchon Hutschraube Vite mordente 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Boulon capuchon 1 9 Hutschraube 1 9 Vite mordente 1 9 Joint torique 2 9 O-Ring 2 9 Anello di tenuta 2 9 Vis de purge d’air 3 9 Entlüftungschraube 3 9 Vite di spurgo dell’aria 3…
• Page 428
  CHAS FRONT FORK 5. Install: 9 Spring guide 1 9 Locknut 2 To damper rod 3. NOTE: 9 Install the spring guide with its cut a facing up- ward. 9 With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6.
• Page 429
  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 5. Monter: 5. Installare: 5. Einbauen: 9 Guide de ressort 1 9 Guida della molla 1 9 Federführung 1 9 Contre-ecrou 2 9 Controdado 2 9 Sicherungsmutter 2 Au tige d’amortisseur 3. Sulla barra dello smorzatore 3. Zum Dämpfungsstange 3.
• Page 430
  CHAS FRONT FORK 9. Install: 9 Slide metal 1 9 Plain washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-01442/90890-01442 10. Install: 9 Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2.
• Page 431
  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 9. Monter: 9. Installare: 9. Einbauen: 9 Bague antifriction 1 9 Metallo di scorrimento 1 9 Gleitmetall 1 9 Rondelle ordinaire 2 9 Rosetta 2 9 Beilegescheibe 2 Vers la fente de tube externe. Sulla fessura del tubo esterno.
• Page 432
  CHAS FRONT FORK 13. Check: 9 Inner tube smooth movement Tightness/Binding/Rough spots ¡ Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: 9 Front fork oil Until outer tube top surface with recom- mended fork oil 1. Recommended oil: Suspension oil “01”…
• Page 433
  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 13. Contrôler: 13. Controllare: 13. Kontrollieren: 9 Mouvement régulier du tube in- 9 Facilità di movimento del tubo 9 Glatte Bewegung des inneres terne interno Rohres Festsitz/Klemmung Raideur/coincement/point dure Difficoltà/Inceppamento /Unregel-mäßige Bewegung ¡Répéter les étapes du 2 au 12. ¡Die Schritte 2 bis 12 wieder- /Ruvidità¡Ripetere le operazio- holen.
• Page 434
  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 435
  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 19. Attendre dix minutes jusqu’à ce 19. Attendere dieci minuti finché le 19. Vor dem Einstellen des empfoh- que les bulles d’air aient été élimi- bolle d’aria sono state tolte dalla lenen Ölpegels, etwa zehn nées de la fourche avant et que forcella anteriore e l’olio si è…
• Page 436
  CHAS FRONT FORK 21. Measure: 9 Distance a Out of specification¡Turn into the locknut. Distance a a : 20 mm (0.79 in) or more Between damper rod 1 1 top and locknut 2 2 top. 22. Loosen: 9 Rebound damping adjuster 1 NOTE: 9 Loosen the rebound damping adjuster finger tight.
• Page 437
  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 21. Mesurer: 21. Misurare: 21. Messen: 9 Distance a 9 Distanza a 9 Maß a Hors spécification¡Rentrer le Fuori specifica¡Avvitare il con- Abweichung von Spezifikation ¡ contre-écrou. trodado. Sicherungsmutter hineindrehen. Distanza a a : Distance a a : Maß…
• Page 438
  CHAS FRONT FORK 26. Tighten: 9 Cap bolt (locknut) 1 29 Nm (2.9 m•kg, 21 ft•lb) NOTE: 9 While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4. 9 Hold the locknut 5 and tighten the cap bolt with specified torque.
• Page 439
  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 26. Serrer: 26. Serrare: 26. Festziehen: 9 Boulon capuchon 1 9 Vite mordente (controdado) 1 9 Hutschraube 1 ft•lb) 29 Nm (2,9 m•kg, 21 ft•lb) 29 Nm (2,9 m•kg, 21 29 Nm (2,9 m•kg, 21 ft•lb) HINWEIS: N.B.: NOTA:…
• Page 440
  CHAS FRONT FORK 4. Tighten: 9 Pinch bolt (handle crown) 1 23 Nm (2.3 m•kg, 17 ft•lb) 9 Pinch bolt (under bracket) 2 20 Nm (2.0 m•kg, 14 ft•lb) Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.

• Page 441: Alla Coppia

  FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 4. Serrer: 4. Serrare: 4. Festziehen: 9 Boulon de bridage (couronne de 9 Bullone di serraggio (corona del 9 Klemmschraube (Lenkerkrone) guidon) 1 manubrio) 1 23 Nm (2,3 m•kg, 17 ft•lb) 23 Nm (2,3 m•kg, 17 ft•lb) 23 Nm (2,3 m•kg, 17 ft•lb) 9 Boulon de bridage (étrier infé- 9 Bullone di serraggio (staffa in-…

• Page 442: Handlebar

  CHAS HANDLEBAR EC5B0000 HANDLEBAR 1 Nm (0.1 m•kg, 0.7 ft•lb) 9 Nm (0.9 m•kg, 6.5 ft•lb) 28 Nm (2.8 m•kg, 20 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 2 Nm (0.2 m•kg, 1.4 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Handlebar removal Extent of removal: Extent of removal…

• Page 443
  GUIDON LENKSTANGE CHAS MANUBRIO GUIDON 1 Dépose du guidon Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU GUIDON Préparation Plaque d’immatriculation Enlever seulement la partie de fixation. pour la dépose Câble d’embrayage Déconnecter du côté levier. Support de levièr d’embrayage Bouton d’arrêt du moteur “ENGINE STOP”…
• Page 444
  CHAS HANDLEBAR EC5B8000 THROTTLE DISASSEMBLY 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Throttle disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks THROTTLE DISASSEMBLY Grip cap (lower) Grip cap (upper) Grip assembly Grip (right) Refer to “REMOVAL POINTS”. Tube guide 5-40…
• Page 445
  GUIDON LENKSTANGE CHAS MANUBRIO DEMONTAGE DE L’ACCELERATEUR 1 Démontage de l’accélérateur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEMONTAGE DE L’ACCELERA- TEUR Capuchon de poigée (inférieur) Capuchon de poigée (supérieur) Ensemble de la poignée Poignée (droite) Se reporter à…
• Page 446
  CHAS HANDLEBAR EC5B3000 REMOVAL POINTS EC5B3100 Master cylinder 1. Remove: 9 Master cylinder bracket 1 9 Master cylinder 2 9 Do not let the master cylinder hang on the brake hose. 9 Keep the master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip 1.
• Page 447
  GUIDON LENKSTANGE CHAS MANUBRIO IC5B3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC5B3100 Maître-cylindre Hauptbremszylinder Cilindro principale 1. Déposer: 1. Ausbausen: 1. Togliere: 9 Etrier de maître-cylindre sur 1 9 Hauptbremszylinderhalterung 9 Staffa del cilindro principale 1 9 Maître-cylindre 2 9 Cilindro principale 2 9 Hauptbremszylinder 2 9 Ne pas laisser pendre le maître-cy-…
• Page 448
  CHAS HANDLEBAR 2. Install: 9 Grip cap (upper) 1 9 Grip cap (lower) 2 9 Bolt (grip cap) 3 NOTE: Temporarily tighten the bolts (grip cap). EC5B5210 Handlebar 1. Install: 9 Handlebar 1 9 Handlebar holder 2 9 Bolt (handlebar holder) 3 28 Nm (2.8 m•kg, 20 ft•lb) NOTE: 9 The upper handlebar holder should be installed…
• Page 449
  GUIDON LENKSTANGE CHAS MANUBRIO 2. Monter: 2. Installare: 2. Einbauen: 9 Capuchon de poignée (supé- 9 Calotta della manopola (supe- 9 Griffkappe (Oben) 1 rieur) 1 riore) 1 9 Griffkappe (Unten) 2 9 Capuchon de poignée (inférieur) 9 Calotta della manopola (inferio- 9 Schraube (Griffkappe) 3 re) 2 HINWEIS:…
• Page 450
  CHAS HANDLEBAR 4. Install: 9 Throttle cable 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throt- tle cable end and tube guide cable winding por- tion. 5. Install: 9 Roller 1 9 Collar 2 NOTE: 9 Apply the lithium soap base grease on the roller sliding surface.
• Page 451
  GUIDON LENKSTANGE CHAS MANUBRIO 4. Monter: 4. Installare: 4. Einbauen: 9 Câble d’accélérateur 1 9 Cavo dell’acceleratore 1 9 Gasseil 1 Au guide de tube 2. Sulla guida del tubo 2. An der Rohrführung 2. HINWEIS: N.B.: NOTA: Appliquer de la graisse à base de savon Applicare sull’estremità…
• Page 452
  CHAS HANDLEBAR 10. Install: 9 Bolt (grip cap) 1 4 Nm (0.4 m•kg, 2.9 ft•lb) 9 Install the grip cap so that the gaps a a and b b between the bolt (grip cap) and brake lever 2 2 are equal. If you make a mistake in the grip cap installation position, the brake lever may contact the grip cap, resulting in poor brake performance.
• Page 453
  GUIDON LENKSTANGE CHAS MANUBRIO 10. Monter: 10. Installare: 10. Einbauen: 9 Boulon (capuchon de poignée) 9 Bullone (calotta della manopo- 9 Schraube (Griffkappe) 1 la) 1 4 Nm (0,4 m•kg, 2,9 ft•lb) 4 Nm (0,4 m•kg, 2,9 ft•lb) 4 Nm (0,4 m•kg, 2,9 ft•lb) 9 Die Griffkappe so einbauen, daß…
• Page 454
  CHAS HANDLEBAR 14. Clamp the clamp portion a of the number plate to the handlebar. 15. Insert the end of the fuel breather hose 1 into the hole of the number plate. 5-45…
• Page 455
  GUIDON LENKSTANGE CHAS MANUBRIO 14. Fixer la partie de fixation a de la 14. Bloccare la parte della brida a 14. Das Klemmteil plaque d’immatriculation au gui- Nummernschildes della targa sul manubrio. don. Lenkstange festklemmen. 15. Inserire l’estremità dello sfiato del carburante 1 nel foro della targa.

• Page 456: Steering

  CHAS STEERING EC560000 STEERING 23 Nm (2.3 m•kg, 17 ft•lb) 145 Nm (14.5 m•kg, 105 ft•lb) TIGHTENING STEPS: 9 Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) 9 Loosen it one turn. 9 Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 1 Under bracket removal 2 Bearing removal Extent of removal:…

• Page 457
  DIRECTION LENKUNG CHAS STERZO DIRECTION ETAPES DE SERRAGE: 9 Serrer l’ecrou annulaire a environ. 38 Nm (3,8 m•kg, 27 ft•lb) 9 Le desserrer d’un tour. 9 Le resserrer a enviorn. 7 Nm (0,7 m•kg, 5,1 ft•lb) 1 Dépose de l’étrier inférieur 2 Dépose du roulement Etendue de dépose: Etendue de dépose…
• Page 458
  CHAS STEERING EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: 9 Ring nut 1 Use the ring nut wrench 2. Ring nut wrench: YU-33975/90890-01403 Support the steering shaft so that it may not fall down. EC563300 Bearing (lower) 1. Remove: 9 Bearing (lower) 1 Use the floor chisel 2.
• Page 459
  DIRECTION LENKUNG CHAS STERZO IC563000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC563202 Ecrou annulaire Ringmutter Ghiera 1. Déposer: 1. Ausbauen: 1. Togilere: 9 Ecrou annulaire 1 9 Ringmutter 1 9 Ghiera 1 Den Ringmutterschlüssel 2 Utiliser la clé pour écrou annu- Usare la chiave per ghiera 2.
• Page 460
  CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a sol- vent. 2. Inspect: 9 Bearing 1 9 Ball race Pitting/Damage ¡ Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand.
• Page 461
  DIRECTION LENKUNG CHAS STERZO IC564101 Roulement et cage à billes Lager und Laufring Cuscinetto e pista 1. Nettoyer les roulements et les 1. Die Lager Laufringe 1. Lavare i cuscinetti e le piste con cages à billes dans du solvant. Lösungsmittel waschen.
• Page 462
  CHAS STEERING 4. Install: 9 Plain washer 1 9 Ring nut 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Tighten the ring nut using the ring nut wrench 3. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAP- TER 3. 5.
• Page 463
  DIRECTION LENKUNG CHAS STERZO 4. Monter: 4. Installare: 4. Einbauen: 9 Rondelle ordinaire 1 9 Rosetta 1 9 Beilegescheibe 1 9 Ecrou annulaire 2 9 Ghiera 2 9 Ringmutter 2 7 Nm (0,7 m•kg, 5,1 ft•lb) 7 Nm (0,7 m•kg, 5,1 ft•lb) 7 Nm (0,7 m•kg, 5,1 ft•lb) Serrer l’écrou annulaire 3 en Ringmutter…
• Page 464
  CHAS STEERING 9. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 10. Adjust: 9 Front fork top end a Front fork top end (standard) a a : Zero mm (Zero in) 11.
• Page 465
  DIRECTION LENKUNG CHAS STERZO 9. Après avoir serré l’écrou, vérifier 9. Dopo avere serrato il dado, con- 9. Nach dem Festziehen der Mutter, si le mouvement de la direction est trollare che lo sterzo si muova sen- die Lenkung auf glatte Bewegung régulier.

• Page 466: Swingarm

  CHAS SWINGARM EC570000 SWINGARM 53 Nm (5.3 m•kg, 38 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 19 Nm (1.9 m•kg, 13 ft•lb) 85 Nm (8.5 m•kg, 61 ft•lb) 80 Nm (8.0 m•kg, 58 ft•lb) 1 Swingarm removal Extent of removal: Extent of removal Order Part name…

• Page 467: Bras Oscillant

  BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE BRAS OSCILLANT 1 Dépose du bras oscillant Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU BRAS OSCILLANT Préparation Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas pour la dépose approprié…

• Page 468
  CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY 80 Nm (8.0 m•kg, 58 ft•lb) 2 Nm (0.2 m•kg, 1.4 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 80 Nm (8.0 m•kg, 58 ft•lb) 1 Swingarm disassembly 2 Connecting rod removal and disassembly Extent of removal: 3 Relay arm removal and disassembly Extent of removal Order…

• Page 469: Forcellone Oscillante

  BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE DEMONTAGE DU BRAS OSCILLANT 1 Démontage du bras oscillant 2 Dépose et démontage de la bielle Etendue de dépose: 3 Dépose et démontage du bras de relais Etendue de dépose Ordre Nom de pièce Q’té…

• Page 470
  CHAS SWINGARM EC573000 REMOVAL POINTS EC573201 Bearing 1. Remove: 9 Bearing 1 NOTE: Remove the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes, collars, and covers in a solvent. EC574111 Swingarm 1. Inspect: 9 Bearing 1 9 Bush 2 Free play exists/Unsmooth revolution/Rust ¡…
• Page 471
  BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE IC573000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC573201 Cuscinetto Roulement Lager 1. Togliere: 1. Déposer: 1. Ausbauen: 9 Cuscinetto 1 9 Roulement 1 9 Lager 1 NOTA: N.B.: HINWEIS: Togliere il cuscinetto premendone Déposez le roulement en appuyant sur Lager durch Drücken auf den äusse- l’anello esterno.
• Page 472
  CHAS SWINGARM EC574311 Connecting rod 1. Inspect: 9 Bearing (polylube bearing) 1 9 Collar 2 Free play exists/Unsmooth revolution/Rust ¡ Replace bearing and collar as a set. 2. Inspect: 9 Bearing (polylube bearing) 1 Loss of solid lubrication ¡ Replace. 9 Oil seal 3 Damage ¡…
• Page 473
  BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE IC574311 Bielle Pleuelstange Leva di rinvio 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Roulement (roulement Polylu- 9 Lager (Polylube-Lager) 1 9 Cuscinetto (cuscinetto polylube) be) 1 9 Hülse 2 9 Collerette 2 Freies Spiel besteht/Unrunde 9 Bordino 2 Drehung/Rost ¡…
• Page 474
  CHAS SWINGARM 2. Install: 9 Bearing 1 9 Oil seal 2 To relay arm. NOTE: 9 Apply the molybdenum disulfide grease on the bearing when installing. 9 Install the bearing by pressing it on the side hav- ing the manufacture’s marks or numbers. Installed depth of bearings a a : 5 mm (0.20 in) 3.
• Page 475
  BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE 2. Monter: 2. Installare: 2. Einbauen: 9 Roulement 1 9 Cuscinetto 1 9 Lager 1 9 Bague d’étanchéité 2 9 Paraolio 2 9 Öldichtung 2 Au bras de relais. Sul braccio di rinvio. Zum Relaisarm. HINWEIS: N.B.: NOTA:…
• Page 476
  CHAS SWINGARM 3. Install: 9 Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: 9 Connecting rod 1 9 Bolt (connecting rod) 2 9 Plain washer 3 9 Nut (connecting rod) 4 80 Nm (8.0 m•kg, 58 ft•lb) To relay arm 5.
• Page 477
  BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE 3. Monter: 3. Installare: 3. Einbauen: 9 Collerette 1 9 Bordino 1 9 Hülse 1 Au bielle 2. Sulla leva di rinvio 2. Zum Pleuelstange 2. HINWEIS: N.B.: NOTA: Appliquer de la graisse de molybdéne Applicare il grasso a base di bisolfuro Molybdän-Fett auf den Hülse und…
• Page 478
  CHAS SWINGARM 7. Check: 9 Swingarm side play a Free play exists ¡ Replace thrust bearing. 9 Swingarm up and down movement b Unsmooth movement/Binding/Rough spots¡Grease or replace bearings, bushes and collars. 8. Install: 9 Bolt (connecting rod) 1 9 Plain washer 2 9 Nut (connecting rod) 3 NOTE: 9 Apply the molybdenum disulfide grease on the…
• Page 479
  BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE 7. Contrôler: 7. Controllare: 7. Kontrollieren: 9 Jeu latéral du bras oscillant a 9 Gioco laterale del forcellone 9 Seitliches Spiel der Hinterrad- ¡ schwinge a oscillante a Il y a jeu fonctionnel Esiste gioco ¡ Sostituire il cu- Freies Spiel besteht ¡…
• Page 480
  CHAS SWINGARM 12. Install: 9 Cap 1 NOTE: Install the cap (right) with its mark a facing for- ward. 13. Install: 9 Bolt [chain tensioner (lower)] 1 9 Plain washer 2 9 Collar 3 9 Chain tensioner 4 9 Nut [chain tensioner (lower)] 5 19 Nm (1.9 m•kg, 13 ft•lb) 14.
• Page 481
  BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE 12.Monter: 12. Installare: 12. Einbauen: 9 Capuchon 1 9 Coperchio 1 9 Kappe 1 HINWEIS: N.B.: NOTA: Installer le capuchon (droit) avec le Posizionare il coperchio (destra) con il Kappe (rechts) mit ihrer Kennzeich- repère a vers l’avant.
• Page 482
  CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER 56 Nm (5.6 m•kg, 40 ft•lb) 53 Nm (5.3 m•kg, 38 ft•lb) 32 Nm (3.2 m•kg, 23 ft•lb) 29 Nm (2.9 m•kg, 21 ft•lb) 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal: Extent of removal Order…

• Page 483: Et Couvercles Lateraux

  AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE AMORTISSEUR ARRIERE 1 Dépose de l’amortisseur arrière 2 Démontage de l’amortisseur arrière Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE L’AMORTISSEUR ARRIERE Bien soutenir la machine afin qu’elle ne risque pas Préparation Maintenir la machine en plaçant un support de se renverser.

• Page 484
  1. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. To dispose of a damaged or worn-out shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5-60…

• Page 485: Ammortizzatore Posteriore

  IC587000 REMARQUE CONCER- NOTE SULLO SMALTI- VERSCHROTTUNGSANLEI- MENTO (SOLTANTO CON- NANT LA MISEAU REBUT DE L’AMORTISSEUR TUNG (NUR FÜR YAMAHA CESSIONARI YAMAHA) Prima di smaltire l’ammortizzatore, as- (TRAVAIL A EFFECTUER FACHHÄNDLER) sicurarsi di estrarre l’azoto gassoso dal- Verschrotten CHEZ UN CONCESSION- la valvola 1.

• Page 486
  CHAS REAR SHOCK ABSORBER EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: 9 Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: 9 Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3.
• Page 487
  AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE IC583000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC583320 Roulement Lager Cuscinetto 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Bague d’arrêt (roulement supé- 9 Anschlagring (Oben Lager) 1 9 Anello di fermo (cuscinetto su- rieur) 1 periore) 1 HINWEIS:…
• Page 488
  CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585320 Bearing 1. Install: 9 Upper Bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear- ing is press fitted.
• Page 489
  AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE IC585000 REMONTAGE ET MONTA- MONTAGE UND EINBAU MONTAGGIO E INSTAL- LAZIONE IC585320 Lager Roulement Cuscinetto 1. Einbauen: 1. Monter: 1. Installare: 9 Oben Lager 1 9 Roulement supérieur 1 9 Cuscinetto superiore 1 HINWEIS: N.B.: NOTA: Das Lager am äußeren Laufring paral-…
• Page 490
  CHAS REAR SHOCK ABSORBER 3. Adjust: 9 Spring length (installed) a Spring length (installed) a a : Standard Extent of length adjustment 251 mm (9.88 in) 240.5~258.5 mm (9.47~10.18 in) *261 mm (10.28 in) *255.5~273.5 mm (10.06~10.77 in) *For EUROPE NOTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster.
• Page 491
  AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE 3. Régler: 3. Regolare: 3. Einstellen: 9 Longueur de ressort a 9 Lunghezza della molla (installa- 9 Länge der Feder a ta) a Länge der Feder (einge- Longueur de ressort baute)a: Lunghezza della molla (monté)a: (installata)a: Standard-.
• Page 492
  CHAS REAR SHOCK ABSORBER 3. Install: 9 Rear shock absorber 4. Install: 9 Bolt (rear shock absorber-frame) 1 9 Nut (rear shock absorber-frame) 2 56 Nm (5.6 m•kg, 40 ft•lb) NOTE: Apply the molybdenum disulfide grease on the bolt. 5. Install: 9 Bolt (rear shock absorber-relay arm) 1 9 Nut (rear shock absorber-relay arm) 2 53 Nm (5.3 m•kg, 38 ft•lb)
• Page 493
  AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE 3. Monter: 3. Installare: 3. Einbauen: 9 Amortisseur arrière 9 Ammortizzatore posteriore Hinterrad-Stoßdämpfer 4. Monter: 4. Installare: 4. Einbauen: 9 Boulon (ammortisseur arrière— 9 Bullone (ammortizzatore poste- Schraube (Hinterrad-Stoß- cadre) 1 riore–telaio) 1 dämpfer—Rahmen) 1 9 Ecrou (amortisseur arrière—…

• Page 494: Wiring Diagram

  ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS COLOR CODE B….Black 1 CDI unit L ….Blue 2 “ENGINE STOP” button 3 Ignition coil O ….Orange R ….Red 4 TPS (throttle position sensor) Y….Yellow 5 Solenoid valve 6 CDI magneto…

• Page 495: Elektrische Einrichtungen

  COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN ELEC COMPONENTI ELETTRICI E SCHEMA ELETTRICO IC600000 PARTIE ELETRIQUE ELEKTRISCHE PARTE ELETTRICA COMPOSANTS EINRICHTUNGEN IC610000 ELECTRIQUES ET COMPONENTI ELEKTRISCHE BAUTEILE SCHEMA DE CABLAGE ELETTRICI E SCHEMA UND SCHALTPLAN COMPOSANTS ELECTRIQUES ELETTRICO ELEKTRISCHE BAUTEILE 1 Bloc CDI…

• Page 496: Ignition System

  ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM EC621003 INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark *Clean or replace Spark gap test spark plug.

• Page 497
  ELEC SYSTEME D’ALLUMAGE SYSTEME D’ALLUMAGE ETAPES DE VERIFICATION Utiliser les étapes suivantes pour vérifier la possibilité d’attribution du mauvais fonctionnement du moteur à une panne du circuit d’allumage et pour vérifier la bougie d’allumage qui n’allume pas. Etincelle Essai de l’intervalle d’étincellement *Nettoyer ou remplacer d’allumage.
• Page 498
  ELEC ZÜNDANLAGE ZÜNDANLAGE PRÜFVORGÄNGE Durch folgende Schritte auf eine mögliche Störung des Motors durch einen Defekt im Zündsystem prü- fen und Ausfindigmachen einer aussetzenden Zündkerze. Zündfunke *Zündkerze reinigen oder Test der Zündfunkenstrecke erneuern. Kein Zündfunke Die Anschlüsse der gesamten Nicht in Ordnung Erneuern oder reparieren.
• Page 499
  ELEC SISTEMA DI ACCENSIONE IC620000 SISTEMA DI ACCENSIONE IC621003 OPERAZIONI DI ISPEZIONE Usare le operazioni che seguono per controllare la possibilità che il malfunzionamento del motore sia attribuibile a un guasto del sistema di accensione e per controllare la candela che non emette scintille. Scintilla Test della distanza tra gli elettrodi *Pulire o sostituire la candela.
• Page 500
  ELEC IGNITION SYSTEM å å EC622001 SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (igni- tion checker 2 ) as shown. 9 Spark plug cap 3 9 Spark plug 4 A For USA and CDN B Except for USA and CDN 3.

• Page 501: Verification Des Connexions

  SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE IC622001 ESSAI DE L’INTERVALLE TEST DER ZÜNDFUNKENSTRECKE TEST DELLA DISTANZA TRA D’ETINCELLEMENT 1. Den Zündkerzenstecker von der GLI ELETTRODI D’ALLUMAGE Zündkerze abtrennen. 1. Scollegare la calotta della candela 1. Déconnecter le capuchon de bou- 2.

• Page 502
  ELEC IGNITION SYSTEM EC626003 IGNITION COIL INSPECTION 1. Inspect: 9 Primary coil resistance Out of specification ¡ Replace. Tester (+) lead ¡ Orange lead 1 Tester (–) lead ¡ Black lead 2 Primary coil Tester selector resistance position 0.20~0.30Ω at Ω…
• Page 503
  SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE IC626003 VERIFICATION DE LA BOBINE INSPEKTION DER ZÜNDSPULE ISPEZIONE DELLA BOBINA DI D’ALLUMAGE 1. Prüfen: ACCENSIONE 9 Widerstand der Primärspule 1. Examiner: 1. Ispezionare: 9 Résistance de bobine primaire Abweichung von Spezifikation 9 Resistenza della bobina prima- Hors spécification ¡…
• Page 504
  ELEC IGNITION SYSTEM EC62B000 SPARK PLUG CAP INSPECTION 1.Inspect: 9 Spark plug cap Loose connection ¡ Tighten. Deteriorated/Damaged ¡ Replace. 9 Spark plug cap resistance Out of specification ¡ Replace. Tester (+) lead ¡Spark plug lead terminal 1 Tester (–) lead ¡Spark plug terminal 2 Spark plug cap Tester selector resistance…

• Page 505: Magneto Cdi

  SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE IC62B000 INSPECTION DU CAPUCHON DE PRÜFEN DES CONTROLLO DEL CAPPUCCIO BOUGIE ZÜNDKERZENSTECKERS DELLA CANDELA 1. Examiner: 1. Prüfen: 1.Ispezionare: 9 Capuchon de bougie 9 Zündkerzenstecker 9 Cappuccio della candela Connexion lâche ¡ Serrez. Lose Verbindung ¡…

• Page 506
  ELEC IGNITION SYSTEM 3. Inspect: 9 Source coil 2 resistance Out of specification ¡ Replace. Tester (+) lead ¡Green/ Blue lead 1 Tester (–) lead ¡Green/ White lead 2 Source coil 2 Tester selector resistance position 44~66Ω at Ω × 10 20°C (68°F) EC628000 CDI UNIT INSPECTION…
• Page 507
  SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE 3. Examiner: 3. Ispezionare: 3. Prüfen: 9 Résistance de bobine de source 9 Resistenza della bobina sorgen- 9 Widerstand der Stromspule 2 te 2 Abweichung von Spezifikation Hors spécification ¡ Changer. Fuori specifica ¡ Sostituirla. ¡…

• Page 508: Solenoid Valve System

  ELEC SOLENOID VALVE SYSTEM EC650001 SOLENOID VALVE SYSTEM EC651032 INSPECTION STEPS If the solenoid valve will not operate, use the following inspection steps. No good Check each couplers and Repair or replace. wire connection. No good Check solenoid Check solenoid valve. Replace.

• Page 509: Systeme D’electrovanne

  ELEC SYSTEME D’ELECTROVANNE SYSTEME D’ELECTROVANNE ETAPES DE VERIFICATION Si l’électrovanne ne fonctionne pas, applicuez la proqédure d’inspection suivante. Mauvais Vérifiez chaque coupleur et chaque Changer ou réparer. connexion de fil. O.K. Mauvais Vérifiez le bon fonctionne- Vérifiez l’électrovanne. Changer. ment de l’électrovanne. Mauvais Magnetventilspule Changer.

• Page 510: Spezialwerkzeuge

  ELEC MAGNETVENTILSYSTEM MAGNETVENTILSYSTEM PRÜFVORGÄNGE Falls das Magnetventil nicht funktioniert, sind die folgenden Überprüfungen durchzuführen. Nicht in Ordnung Erneuern oder Alle Stecker — und Kabelverbin- reparieren. dungen überprüfen. In Ordnung Nicht in Ordnung Betriebsablauf des Magnetventil überprüfen. Erneuern. Magnetventils prüfen. Nicht in Ordnung Magnetventilspule Erneuern.

• Page 511: Utensili Speciali

  ELEC SISTEMA ELETTROVALVOLA IC650001 SISTEMA ELETTROVALVOLA IC651032 OPERAZIONI DI ISPEZIONE Se l’elettrovalvola non funziona, effettuare i seguenti controlli. Non funziona Controllare tutti gli accoppiatori e i Ripararlo o sostituirlo. collegamenti dei fili. Non funziona Controllare il funziona- Controllare l’elettrovalvola. Sostituirlo. mento dell’elettrovalvola.

• Page 512: Solenoid Valve System

  ELEC SOLENOID VALVE SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: 9 Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ¡ Repair or replace. EC652040 SOLENOID VALVE OPERATION 1. Disconnect the solenoid valve coupler. 2. Connect 12V battery to the solenoid valve coupler.

• Page 513
  SYSTEME D’ELECTROVANNE MAGNETVENTILSYSTEM ELEC SISTEMA ELETTROVALVOLA IC624000 VERIFICATION DE CONNEXION INSPEKTION DES ANSCHLUSSES ISPEZIONE DEL DES COUPLEURS ET FILS DER KUPPLUNGEN UND KABEL COLLEGAMENTO DI 1. Contrôler: 1. Kontrollieren: ACCOPPIATORI E CONDUTTORI 9 Connexion des coupleurs et fils 9 Anschluß deren Kupplungen 1.

• Page 514: Tps (Throttle Position Sensor System

  ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM EC690000 TPS (THROTTLE POSITION SENSOR) SYSTEM EC691001 INSPECTION STEPS If the TPS will not operate, use the following inspection steps. No good Check entire ignition Repair or replace. system for connection. No good Check TPS. TPS coil Replace.

• Page 515
  SYSTEME TPS (CAPTEUR DE POSITION DU ELEC PAPILLON) SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) ETAPES DE VERIFICATION Si le TPS ne fonctionne pas, appliquez la procédure d’inspection suivante. Contrôler du système entierd’allumage Mauvais Changer ou réparer. pour les connexions. O.K.
• Page 516
  ELEC TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) PRÜFVORGÄNGE Falls das TPS nicht funktioniert, sind die folgenden Überprüfungen durchzuführen. Die Anschlüsse der gesamten Nicht in Ordnung Erneuern oder reparieren. Zündanlage kontrollieren. In Ordnung Nicht in Ordnung TPS kontrollieren. TPS-Spule Erneuern.
• Page 517
  SISTEMA TPS (SENSORE DI POSIZIONE ELEC DELL’ACCELERATORE) IC690000 SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) IC691001 OPERAZIONI DI ISPEZIONE Se il TPS non funziona, effettuare i seguenti controlli. Controllare il collegamento dell’intero Non funziona Ripararlo o sostituirlo. sistema di accensione. Non funziona Controllare il TPS.
• Page 518
  ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM EC69A000 HANDLING NOTE Do not loosen the screws {TPS (throttle position sensor)} except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1.

• Page 519: Vergaser Und Zungenventil

  SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) ELEC SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) IC69A000 REMARQUES CONCERNANT LA HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO MANIPULATION Schrauben des TPS-Leitungskabels Non allentare le viti [conduttore TPS Ne pas desserrer les vis du fil du cap- (Drosselstellungssensor) nur dann (sensore di posizione gas)] se non per teur de position du papillon (TPS),…

• Page 520
  ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 3. Inspect: 9 TPS coil variable resistance Check that the resistance in increased as the lever 1 is moved from the full close position to the full open position. Out of specification ¡ Replace. Tester (+) lead ¡Yellow lead 2 Tester (–) lead ¡Black lead 3 TPS coil variable…
• Page 521
  SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) ELEC SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) 3.Examiner: 3. Ispezionare: 3.Prüfen: 9 Résistance variable de la bobine 9 Resistenza variabile della bobi- 9 Regelbarer TPS-Spulenwider- du TPS na del TPS stand Vérifier si la résistance augmen- Controllare che la resistenza…
• Page 522
  ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 4. Install: 9 TPS 1 9 Screw (TPS) 2 NOTE: 9 Align the slot a in the TPS with the projection b on the carburetor while the lever 3 is held down. 9 Temporarily tighten the screws (TPS). 5.
• Page 523
  SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) ELEC SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) 4. Monter: 4. Installare: 4. Ausbauen: 9 TPS 1 9 TPS 1 9 TPS 1 9 Vis (TPS) 2 9 Vite (TPS) 2 9 Schraube (TPS) 2 HINWEIS: N.B.:…
• Page 524
  ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 8. Start the engine. 9. Adjust: 9 TPS output voltage Adjustment steps: Adjust the installation angle of the TPS 1 to obtain the specified output volt- age. TPS output Tester selector voltage position 0.5~0.7V DCV-20 10.
• Page 525
  SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) ELEC SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) 8. Démarrer le moteur. 8. Avviare il motore. 8. Den Motor anlassen. 9. Régler: 9. Regolare: 9. Einstellen: 9 Tension de sortie TPS 9 Tensione d’uscita del TPS 9 TPS-Ausgangsspannung Einstellschritte:…
• Page 526
  ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM EC694000 TPS INPUT VOLTAGE INSPECTION 1. Disconnect the TPS coupler. 2. Start the engine. 3. Inspect: 9 TPS input voltage Out of specification ¡ Replace the CDI unit. Tester (+) lead ¡Blue lead 1 Tester (–) lead ¡Black/Blue lead 2 TPS input Tester selector…
• Page 527
  SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) ELEC SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) IC694000 VERIFICATION DE LA TENSION KONTROLLE DER TPS-EINGANGS- ISPEZIONE DELLA TENSIONE IN D’ENTREE DU TPS SPANNUNG INGRESSO NEL TPS 1. Déconnecter le coupleur du TPS. 1.
• Page 528
  SETTING EC700000 TUNING EC710000 ENGINE EC711001 Carburetor setting 9 The role of fuel is to cool the engine, and in the case of a 2-stroke engine, to lubricate the engine in addition to power generation. Accord- ingly, if a mixture of air and fuel is too lean, abnormal combustion will occur, and engine seizure may result.
• Page 529
  REGLAGE EINSTELLUNG REGISTRAZIONE IC700000 MISE AU POINT TUNING MESSA A PUNTO MOTEUR MOTOR IC710000 Réglage du carburateur Vergasereinstellung MOTORE 9 Le rôle du carburant consiste à 9 Zusätzlich zu der Krafterzeugung IC711001 refroidir le moteur et dans le cas dient der Kraftstoff auch zur Kühlung Registrazione del carburatore d’un moteur à…
• Page 530
  SETTING That is: 9 Higher temperature expands the air with its resultant reduced density. 9 Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air. 9 Lower atmospheric pressure (at a high altitude) reduces the density of the air.
• Page 531
  REGLAGE EINSTELLUNG REGISTRAZIONE Ainsi: Cioè: Das heißt: 9 Une température plus élevée dilate 9 Una temperatura più alta fa dilatare 9 Eine höhere Temperatur führt zu l’air et en réduit la densité. l’aria; ne risulta una densità ridotta. einer Ausdehnung der Luft und 9 Une humidité…
• Page 532
  SETTING EC714032 Effects of setting parts in relation to throt- tle valve opening Throttle valve opening Setting part Full-closed 1/4 3/4 Full-open Pilot jet Pilot air screw Diameter of straight portion Clip position Throttle valve Power jet Main jet NOTE: The power jet closes at 8,500 rpm of the engine, after which only the main jet dominates.
• Page 533
  REGLAGE EINSTELLUNG REGISTRAZIONE IC714032 Ajustement de pièces à l’ouverture Wirkung der Einstellteile in Bezie- Effetto delle parti di registrazione in du papillon des gaz hung zur Öffnung der Drosselklappe relazione all’apertura della valvola regolatrice del flusso Ouverture du papillon des gaz Drosselklappenöffnung Pièce de réglage Fermé…
• Page 534
  SETTING EC716001 Pilot air screw adjustment The richness of air-fuel mixture with full closed to 1/8 throttle can be set by turning the pilot air screw 1. Turning in the pilot air screw will enrich the mix- ture at low speeds, and turning out it will lean out the mixture.
• Page 535
  REGLAGE EINSTELLUNG REGISTRAZIONE IC716001 Réglage de la vis de richesse Einstellung der Leerlauf-Luftregu- Regolazione della vite dell’aria pilota La richesse du mélange air-carburant lierschraube La ricchezza della miscela aria-carbu- avec le papillon des gaz fermé à 1/8 Der Kraftstoffgehalt des Luft/Kraftstoffge- rante con la valvola regolatrice del flus- peut être réglée en tournant la vis de misches bei vollständig geschlossener…
• Page 536
  SETTING 1. Too rich at intermediate speeds Rough engine operation is felt and the engine will not pick up speed smoothly. In this case, step up the jet needle clip by one groove and move down the needle to lean out the mixture.
• Page 537
  REGLAGE EINSTELLUNG REGISTRAZIONE 1. Trop riche aux régimes intermé- 1. Zu fett bei mittleren Drehzahlen 1. Troppo ricca a regimi intermedi diaires Rauher Motorbetrieb kann festge- Si sente che il motore funziona in Le fonctionnement du moteur est stellt werden und der Motor kann maniera discontinua e riprende irrégulier et le moteur ne prend pas nicht glatt beschleunigt werden.
• Page 538
  SETTING EC719081 Jet needle adjustment (For USA, CDN, ZA, AUS and NZ) On the carburetors used in the YZ250, the main nozzle is press-fitted, so it can not be replaced. Therefore, carburetor setting requires the change of the jet needle. 1.
• Page 539
  REGLAGE EINSTELLUNG REGISTRAZIONE IC719081 Réglage de l’aiguille de gicleur Düsennadel-Einstellung Regolazione dell’ago a getto (Pour USA, CDN, ZA, AUS et NZ) (Für USA, CDN, ZA, AUS und NZ) (Per USA, CDN, ZA, AUS e NZ) Sur les carburateurs utilisés pour le An den in das Modell YZ250 ver- Sui carburatori usati nella YZ250, YZ250, la buse princi;ase est forcée et…
• Page 540
  SETTING EC719081 Jet needle adjustment (For EUROPE) On the carburetors used in the YZ250, the main nozzle is press-fitted, so it can not be replaced. Therefore, carburetor setting requires the change of the jet needle. 1. The jet needle setting parts, having the same taper angle, are available in different straight portion diameters and in different taper start- ing positions.
• Page 541
  REGLAGE EINSTELLUNG REGISTRAZIONE IC719081 Réglage de l’aiguille de gicleur Düsennadel-Einstellung Regolazione dell’ago a getto (Pour EUROPE) (Für EUROPA) (Per EUROPA) Sur les carburateurs utilisés pour le An den in das Modell YZ250 ver- Sui carburatori usati nella YZ250, YZ250, la buse princi;ase est forcée et wendeten Vergasern ist der Hauptzer- l’ugello principale è…
• Page 542
  SETTING EC71B011 Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet needle. On the relationship between the fuel flow and the throttle opening, the fuel flow relates to the jet needle straight por- tion diameter around 1/8 to 1/4 throttle opening,…
• Page 543
  REGLAGE EINSTELLUNG REGISTRAZIONE IC71B011 Relation avec l’ouverture du papillon Zusammenhang mit der Drosselöff- Rapporto con l’apertura della valvo- L’arrivée du carburant dans le système nung la a farfalla principal du carburateur est contrôlée Die durch das Vergaser-Hauptsystem Il flusso del carburante attraverso il par le gicleur principal, puis est encore strömende Kraftstoffmenge wird durch sistema principale del carburatore è…
• Page 544
  SETTING EC71Q000 Carburetor setting parts Part name Size Part number Main jet 1 1 Rich #190 4MX-14943-45 #188 4MX-14943-95 #185 4MX-14943-44 #182 4MX-14943-94 *(STD) #180 4MX-14943-43 (STD) #178 4MX-14943-93 #175 4MX-14943-42 #172 4MX-14943-92 #170 4MX-14943-41 #168 4MX-14943-91 #165 4MX-14943-40 Lean #162 4MX-14943-90 Pilot jet 2 2…
• Page 545
  REGLAGE EINSTELLUNG REGISTRAZIONE IC71Q000 Pièces de réglage du carburateur Vergaser-Einstellteile Parti di regolazione del carburatore Teilebezeichnung Größe Teilenummer Numéro Particolare Dimen- Numero Nom de pièce Taille de pièce sioni categorico Haupt- Fett #190 4MX-14943-45 düse 1 1 #188 4MX-14943-95 Gicleur Riche #190 4MX-14943-45…
• Page 546
  SETTING EC71C030 Road condition and examples of carburetor setting Conditions General condition Sandy condition Under 10°C 10~25°C Over 25°C Under 10°C 10~25°C Over 25°C (50°F) (50~77°F) (77°F) (50°F) (50~77°F) (77°F) Parts (Winter) (Spring, Autumn) (Summer) (Winter) (Spring, Autumn) (Summer) #178 #180 #178 Main jet…
• Page 547
  SETTING Symptom Setting Checking Number of turns-back ¡ 0~1/4 throttle Use jet needle having a smaller Hard breathing diameter. Correct properly Speed down Overflow from carburetor 0~1/4 throttle Use jet needle having a larger Poor acceleration diameter. White smoke Unstable at low speeds Lower jet needle clip position.
• Page 548
  REGLAGE Conditions de la route et exemples de réglages de carburateur Conditions Générales Sablonneux Moins 10 à 25°C Plus de 25°C Moins de 10 à 25°C Plus de 25°C de 10°C (50°F) (50 à 77°F) (77°F) 10°C (50°F) (50 à 77°F) (77°F) Pièce (Hiver)
• Page 549
  REGLAGE Symptômes Réglages Contrôler Nombre de tours de dévissage ¡ 0~1/4 de papillon Utiliser une aiguille de gicleur avec un Attaque difficile diamètre inférieur. Corriger correctement Perte de vitesse Fuite en provenance du carburateur 0~1/4 de papillon Utiliser une aiguille de gicleur avec un Mauvaise accélération diamètre supérieur.
• Page 550
  EINSTELLUNG Straßenbedingungen und Beispiele für die Vergasereinstellung Normal Sandig Bedingungen Unter 10°C 10~25°C Über 25°C Unter 10°C 10~25°C Über 25°C (50°F) (50~77°F) (77°F) (50°F) (50~77°F) (77°F) Teile (Winter) (Frühling, Herbst) (Sommer) (Winter) (Frühling, Herbst) (Sommer) #178 #180 #178 Hauptdüse #178 #178 #178 *#180…
• Page 551
  EINSTELLUNG Symptom Einstellung Prüfung Anzahl der Ausdrehungen ¡ 0~1/4 Gas Eine Düsennadel mit kleinerem Hartes Beatmen Durchmesser verwenden. Richtig korrigieren Überlauf am Niedrige Drehzahl Vergaser 0~1/4 Gas Eine Düsennadel mit größerem Schlechte Beschleunigung Durchmesser verwenden. Weißer Rauch Unstabil bei niedriger Düsennadel-Klemmenposition Drehzahl absenken.
• Page 552
  REGISTRAZIONE IC71C030 Condizioni stradali ed esempi di registrazione del carburatore Condizioni Condizioni generiche Condizioni di sabbia Meno di 10°C 10~25°C Più di 25°C Meno di 10°C 10~25°C Più di 25°C (50°F) (50~77°F) (77°F) (50°F) (50~77°F) (77°F) Parti (inverno) (primavera, autunno) (estate) (inverno) (primavera, autunno)
• Page 553
  REGISTRAZIONE Sintomo Registrazione Controllo Numero di giri in senso contrario ¡ Valvola a farfalla a 0 ~ 1/4 Usare un ago a getto che abbia un Respirazione difficoltosa diametro più piccolo. Correggere adeguatamente Velocità bassa Traboccamento dal carburatore Valvola a farfalla a 0 ~ 1/4 Usare un ago a getto che abbia un Accelerazione scarsa diametro più…
• Page 554
  SETTING EC71M010 Change of the heat range of spark plugs Judging from the discoloration of spark plugs, if they are found improper, it can be corrected by the following two methods; changing carburetor settings and changing the heat range of spark plug.
• Page 555
  REGLAGE EINSTELLUNG REGISTRAZIONE IC71M010 Changement de plage de chaleur des Änderung des Wärmebereichs der Cambiamento della gamma termica bougies Zündkerzen delle candele En fonction de la décoloration des bou- Falls anhand der Verfärbung der Giudicando dallo scolorimento delle gies, si elle n’est pas normale, elle peut Zündkerzen eine falsche Einstellung candele, se si rileva che sono inadegua- être corrigée par les deux méthodes qui…
• Page 556
  SETTING EC720000 CHASSIS EC71P002 Selection of the secondary reduction ratio (Sprocket) Secondary Number of driven sprocket teeth reduction Number of drive sprocket teeth ratio Standard secondary 50/14 (3.571) reduction ratio *49/14 (3.500) *For EUROPE and CDN <Requirement for selection of secondary gear reduction ratio>…

• Page 557: Fahrgestell

  REGLAGE EINSTELLUNG REGISTRAZIONE IC720000 PARTIE CYCLE FAHRGESTELL TELAIO Sélection du taux de réduction secon- Auswahl des Sekundär- IC71P002 daire (Pignons) Untersetzungsverhältnisses Selezione del rapporto di riduzione (Kettenrad) secondario (Rocchetto) Nombre de dents du pignon mené Anzahl der Zähne am Numero di denti Taux de réduction angetriebenen Kettenrad del rocchetto condotto…

• Page 558
  SETTING EC72N000 Drive and driven sprockets setting parts Part name Size Part number Drive sprocket 1 1 9383E-13144 (STD) 9383E-14215 Driven sprocket 2 2 5ET-25447-00 5NY-25448-00 *(STD) 5NY-25449-00 (STD) 5NY-25450-00 5NY-25451-00 5NY-25452-00 *For EUROPE and CDN EC721003 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit.
• Page 559
  REGLAGE EINSTELLUNG REGISTRAZIONE IC72N000 Pièces de réglage des pignons méné et Antriebs- und Abtriebskettenrad- Parti di regolazione del rocchetto menant Einstellteile conduttore e condotto Teilebezeichnung Größe Teilenummer Numéro Dimen- Numero Nom de pièce Taille Particolare de pièce sioni categorico Antriebskettenrad 9383E-13144 (STD) 9383E-14215…
• Page 560
  SETTING EC722011 Front fork setting The front fork setting should be made depending on the rider’s feeling of an actual run and the cir- cuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics 9 Change the fork oil level.

• Page 561: Fourche Avant

  REGLAGE EINSTELLUNG REGISTRAZIONE IC722011 Réglages de la fourche avant Einstellung der Vorderradgabel Registrazione della forcella anteriore Régler la fourche avant en fonction de Die Einstellung der Vorderradgabel La registrazione della forcella anteriore la sensation lors de la conduite ainsi soll entsperechend dem Gefühl des dovrebbe essere effettuata in base alla sen- que des conditions du terrain.

• Page 562
  SETTING EC727021 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. Do not install three or more adjustment washers for each front fork. Always adjust each front fork to the same setting.
• Page 563
  REGLAGE EINSTELLUNG REGISTRAZIONE IC727021 Réglage de tension initiale du ressort Einstellung der Federvorspannung Regolazione del precarico della molla Le tension initiale du ressort a été ajus- Die Federvorspannung wird einge- Il precarico della molla viene regolato tée en montant la rondelle de réglage 1 stellt, indem die Einstellscheibe 1 installando la rondella di regolazione entre le ressort de fourche 2 et la tige…
• Page 564
  SETTING 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of con- tact with the road surface or in a vibrating handlebar. To set a stiff spring: 9 Change the rebound damping.
• Page 565
  REGLAGE EINSTELLUNG REGISTRAZIONE 2. Ressort dur 2. Uso di una molla rigida 2. Verwendung einer harten Feder En principe, un ressort dur offre Generalmente una molla rigida dà Normaleweise bewirkt eine harte une sensation de conduite dure. La una sensazione di guida rigida. Lo Feder ein hartes Fahrgefühl.
• Page 566
  SETTING EC72P010 Front fork setting parts 9 Adjustment washer 1 TYPE (thickness) PART NUMBER T=2.3 mm (0.09 in) 4SS-23364-L0 9 Front fork spring 2 [Equal pitch spring ] I.D. SPRING SPRING TYPE MARK RATE PART NUMBER (slits) 0.380 4SS-23141-10 0.390 4SS-23141-20 I-II SOFT…
• Page 567
  REGLAGE EINSTELLUNG REGISTRAZIONE IC72P010 Pièces de réglage de la fourche avant Vorderradgabel-Einstellteile Parti di regolazione della forcella 9 Rondelle de réglage 1 9 Einstellscheibe 1 anteriore 9 Rondella di regolazione 1 TYPE (epaisseur) NUMERO DE PIECE TYP (Dicke) TEILENUMMER TIPO (spessore) NUMERO CATEGORICO T=2,3 mm (0,09 in) 4SS-23364-L0 T=2,3 mm (0,09 in)
• Page 568
  SETTING EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the follow- ing two factors: 1. Setting of spring preload 9 Change the set length of the spring.
• Page 569
  REGLAGE EINSTELLUNG REGISTRAZIONE IC72B000 Réglage de la suspension arrière Einstellung der Hinterradfederung Registrazione della sospensione posteriore Effectuer le réglage de la suspension Die Einstellung der Hinterradfederung La registrazione della sospensione arrière en fonction de la sensation lors soll entsprechend dem Gefühl des posteriore dovrebbe essere effettuata in de la conduite ainsi que des conditions Fahrers nach einer Testfahrt und den…
• Page 570
  SETTING NOTE: 9 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. 9 If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make re-adjustment.
• Page 571
  REGLAGE EINSTELLUNG REGISTRAZIONE N.B.: HINWEIS: NOTA: 9 Le ressort peut s’allonger au fur et à 9 Se il veicolo è nuovo e dopo il rodag- 9 Wenn eine neue Maschine eingefah- mesure de la période de rodage. Il est gio, la stessa lunghezza registrata ren worden ist, kann es sein, daß…
• Page 572
  SETTING When using a rear cushion other than cur- rently installed, use the one whose overall length a a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Length a a of standard shock: 490.5 mm (19.31 in) å…
• Page 573
  REGLAGE EINSTELLUNG REGISTRAZIONE Lors du remplacement du ressort de Quando si usa un ammortizzatore Bei Verwendung eines anderen hin- la suspension arrière, veiller à mon- posteriore diverso da quello attual- teren Stoßdämpfers ter un ressort dont la longueur totale mente installato, usarne uno la cui momentan eingebauten verwenden a a n’excède pas la longueur standard lunghezza totale a a non superi quella…
• Page 574
  SETTING EC72Q011 Rear shock absorber setting parts 9 Rear shock spring 1 [Equal pitch spring ] I.D. SPRING SPRING SPRING TYPE COLOR FREE RATE PART NUMBER /POINT LENGTH 5UN-22212-00 Brown/1 SOFT 5UN-22212-10 Green/1 5UN-22212-20 Red/1 5UN-22212-30 Black/1 5UN-22212-40 Blue/1 5UN-22212-50 Yellow/1 STIFF 5UN-22212-60…
• Page 575
  REGLAGE EINSTELLUNG REGISTRAZIONE IC72Q011 Pièces de réglage de l’amortisseur Hinterradstoßdämpfer-Einstellteile Parti di regolazione dell’ammortizza- 9 Hinterradstoßdämpfer-Schrauben arrière tore posteriore 9 Ressort d’amortisseur arrière 1 feder 1 9 Molla dell’ammortizzatore posteriore [Ressort à pas égal] [Feder mit gleichmäßiger Gewinde- steigung] [Molla di passo unguale] CONSTANTE NUMERO DE REPERE Longueur FEDER- I.D.MAR-…

• Page 576: Suspension Setting

  SETTING EC72H010 Suspension setting 9 Front fork NOTE: 9 If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. 9 Before any change, set the rear shock absorber sunken length to the standard figure 90~100 mm (3.5~3.9 in).

• Page 577
  SETTING 9 Rear shock absorber NOTE: 9 If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. 9 Adjust the rebound damping in 2-click increments or decrements. 9 Adjust the low compression damping in 1-click increments or decrements.
• Page 578
  REGLAGE Réglage de la suspension 9 Fourche avant N.B.: 9 Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectur un nouveau réglage en se référant aux procédés repris dans ce tableau. 9 Avant d’effectuer toute modification, régler la longueur enfoncée de l’amortisseur arrière à la valeur stan- dard de 90~100 mm (3,5~3,9 in).
• Page 579
  REGLAGE 9 Amortisseur arrière N.B.: 9 Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, ettectur un nouveau réglage en se référant aux procédés repris dans ce tableau. 9 Ajuster la force de rebond par incréments et décréments de 2 déclics. 9 Ajuster la force d’amortissement de compression basse par incréments ou décréments de 1 déclic.
• Page 580
  EINSTELLUNG Federungseinstellung 9 Vorderradgabel HINWEIS: 9Wenn eines der folgenden Symptome mit der Standardeinstellung als Basis auftritt, nehmen Sie eine Nachstellung unter Beachtung der in der Tabelle gezeigten Einstellschritte vor. 9Vor jeder Änderung stellen Sie die eingetauchte Länge des Hinterrad-Stoßdämpfers auf den Stan- dardwert von 90~100 mm (3,5~3,9 in) ein.
• Page 581
  EINSTELLUNG 9 Hinterradstoßdämpfer HINWEIS: 9Wenn eines der folgenden Symptome mit der Standardeinstellung als Basis auftritt, nehmen Sie eine Nachstellung unter Beachtung der in der Tabelle gezeigten Einstellschritte vor. 9Einstellung der Ausfederdämpfung jeweils in Schritten von 2 Vorwärts- oder Rückwärts-Klickstellun- gen. 9Einstellung der niedrige Einfederdämpfung jeweils in Schritten von 1 Vorwärts- oder Rückwärts-Klick- stellung.
• Page 582
  REGISTRAZIONE IC72H010 Registrazione della sospensione 9 Forcella anteriore NOTA: 9 Se si verifica uno qualsiasi dei seguenti sintomi con la posizione normale come base, effettuare la ri-regi- strazione facendo riferimento alla procedura di registrazione fornita nella stessa tabella. 9 Prima di qualsiasi modifica, registrare la lunghezza abbassata dell’ammortizzatore posteriore sulla cifra normale di 90~100 mm (3,5~3,9 in).
• Page 583
  REGISTRAZIONE 9 Ammortizzatore posteriore NOTA: 9 Se si verifica uno qualsiasi dei seguenti sintomi con la posizione normale come base, effettuare la ri-regi- strazione facendo riferimento alla procedura di registrazione fornita nella stessa tabella. 9 Regolare lo smorzamento dell’estensione in incrementi o decrementi di 2 scatti. 9 Regolare lo smorzamento a bassa compressione in incrementi o decrementi di 1 scatto.
• Page 584
  MEMO…
• Page 586
  YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002.5—1.7 × 1 ! 2500 SHINGAI IWATA SHIZUOKA JAPAN (E, F, G, H)