Página 1 All manuals and user guides at all-guides.com OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGS-HANDBUCH MANUAL DE SERVCIO DEL PROPIETARIO WR450F(S) 5TJ-28199-41...
Página 2 All manuals and user guides at all-guides.com EC010010 WR450F(S) OWNER’S SERVICE MANUAL ©2003 by Yamaha Motor Co., Ltd. 1st Edition, August 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Página 3 Queda expresamente prohibida Verbreitung, auch auszugs- utillisation sans la permission cualquier reimpresión o uso no weise, ist écrite de la Yamaha Motor Co., Ltd. autorizado sin el permiso ohne schriftliche Genehmigung est formellement interdite. por escrito de por Imprimé au Japon Yamaha Motor Co., Ltd.
Página 4 All manuals and user guides at all-guides.com EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
Página 5: Introducción
élevé de la dextérité manuelle et de wurde. Daraus resultiert ein hohes carreras en las que se puede apreciar el la fiabilité qui ont fait de Yamaha un lea- Maß an Qualität und die sprichwörtli- alto grado de manufacturación y fiabili- der.
Página 6: Important Notice
All manuals and user guides at all-guides.com IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal.
Página 7: Zur Beachtung
All manuals and user guides at all-guides.com NOTICE ZUR BEACHTUNG NOTA IMPORTANTE IMPORTANTE Dieses Motorrad ist ausschließlich ESTE VEHÍCULO HA SIDO ESPE- für den Einsatz im Gelände-Renn- CIALMENTE DISEÑADO PARA SU CETTE MACHINE EST STRICTE- sport auf geschlossenen Kursen UTILIZACIÓN COMPETICIO- MENT DESTINEE A LA COMPETI- bestimmt.
Página 8 All manuals and user guides at all-guides.com 5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refu- eling. Take care to not spill any gaso- line on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking.
Página 9 All manuals and user guides at all-guides.com L’ESSENCE EST HAUTE- 5. Benzin ist äußerst entzünd- LA GASOLINA ES ALTA- MENT INFLAMMABLE. MENTE INFLAMABLE. bar und u. U. explosiv. Toujours arrêter le moteur en Apague siempre el motor a la Stellen Sie vor dem Tanken faisant le plein.
Página 10 If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold.
Página 11 Sie sich ou l’entretien de votre machine, veuillez Yamaha. vor Unfällen schützen. consulter votre concessionnaire Yamaha. Este manual debe considerarse como una Wenn Sie die vielen Tips der Bedie- pieza permanente del vehículo y debe N.B.:...
Página 12: How To Use This Manual
All manuals and user guides at all-guides.com EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
Página 13: Comment Utiliser Ce Manuel
All manuals and user guides at all-guides.com COMMENT UTILISER BENUTZERHINWEISE CÓMO UTILIZAR CE MANUEL ESTE MANUAL KENNZEICHNUNG WICH- TIGER HINWEISE INFORMATIONS PARTI- INFORMACIÓN ESPE- CULIEREMENT IMPOR- CIALMENTE IMPOR- TANTES TANTE Ausrufezeichen bedeutet: “GEFAHR! Achten Sie auf Ihre El símbolo de alerta significa: ¡DEBE Sicherheit!”...
Página 14 All manuals and user guides at all-guides.com EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
Página 15 All manuals and user guides at all-guides.com FORMAT DU MANUEL AUFBAU FORMATO DEL MANUAL Diese Anleitung wurde zusammen- Dans ce manuel, toutes les procédures Todos los procedimientos de este gestellt, um dem Benutzer ein leicht sont décrites pas à pas. Les informations manual están organizados secuencial- verständliches Nachschlagewerk in ont été...
Página 16 All manuals and user guides at all-guides.com ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC Illustrated symbols 1 to 7 are designed as INFO thumb tabs to indicate the chapter’s number and content. 1 General information INSP 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical...
Página 17: Símbolos Ilustrados
All manuals and user guides at all-guides.com SYMBOLES ABGEBILDETEN SÍMBOLOS ILUSTRADOS SYMBOL GRAPHIQUES (Consulte la ilustración) (Siehe Abbildung) (Voir l’illustration) Los símbolos ilustrados 1 a 7 están diseñados como lengüetas a seguir con el Die unter 1 bis 7 abgebildeten Les symboles graphiques 1 à...
Página 18 All manuals and user guides at all-guides.com EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...
Página 19: Especificaciones
All manuals and user guides at all-guides.com INDEX INDEX INDEX ALLGEMEINE RENSEIGNEMENTS- INFORMACIÓN GENERAUX GENERAL ANGABEN INFO TECHNISCHE CARACTERISTI- ESPECIFICACIONES QUES DATEN SPEC REGELMÄSSIGE CONTROLES ET AJUSTES E INSPEKTION UND REGLAGES INSPECCIÓN INSP COURANTS REGULARES EINSTELLARBEITEN MOTEUR MOTOR MOTOR PARTIE CYCLE FAHRWERK CHASIS CHAS...
Página 20 All manuals and user guides at all-guides.com EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION ...........1-1 MACHINE IDENTIFICATION .....1-2 IMPORTANT INFORMATION ....1-3 CHECKING OF CONNECTION ....1-6 SPECIAL TOOLS ........1-7 CONTROL FUNCTIONS ......1-10 FUEL ............1-14 STARTING AND BREAK-IN ....1-15 TORQUE-CHECK POINTS ......1-19 CLEANING AND STORAGE ....1-20 CHAPTER 2 SPECIFICATIONS...
Página 21: Tabla De Contenido
All manuals and user guides at all-guides.com TABLES DES INHALT ÍNDICE MATIERES KAPITEL 1 CABÍTULO 1 CHAPITRE 1 ALLGEMEINE INFORMACIÓN RENSEIGNEMENTS ANGABEN GENERAL GENERAUX FAHRZEUGBESCHREIBUNG ...1-1 DESCRIPCIÓN .......1-1 FAHRZEUG- IDENTIFICACIÓN DEL DESCRIPTION .......1-1 IDENTIFIZIERUNG .....1-2 VEHÍCULO ........1-2 IDENTIFICATION WICHTIGE INFORMACIÓN DE LA MACHINE ......1-2 INFORMATIONEN ......1-3 IMPORTANTE .......1-3...
Página 22 All manuals and user guides at all-guides.com CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ........4-1 EXHAUST PIPE AND SILENCER .....4-3 RADIATOR ..........4-5 CARBURETOR ..........4-8 CAMSHAFTS ...........4-21 CYLINDER HEAD ........4-29 VALVES AND VALVE SPRINGS ....4-33 CYLINDER AND PISTON ......4-42 CLUTCH ...........4-48 OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ..4-55...
Página 23 All manuals and user guides at all-guides.com CHAPITRE 4 KAPITEL 4 CABÍTULO 4 MOTEUR MOTOR MOTOR SITZBANK, KRAFTSTOFFTANK SELLE, RESERVOIR ASIENTO, DEPÓSITO UND SEITENABDECKUNGEN ...4-1 A ESSENCE ET DE COMBUSTIBLE KRÜMMER CACHES LATERAUX ....4-1 Y CUBIERTAS LATERALES ..4-1 UND SCHALLDÄMPFER ...4-3 TUYAU D’ECHAPPEMENT TUBO DE ESCAPE KÜHLER ........4-5...
Página 24 All manuals and user guides at all-guides.com CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ......6-1 MAP-CONTROLLED CDI UNIT ....6-2 IGNITION SYSTEM ........6-3 ELECTRIC STARTING SYSTEM ....6-7 CHARGING SYSTEM ......6-17 TPS (THROTTLE POSITION SENSOR) SYSTEM ...........6-19 LIGHTING SYSTEM ........6-24 CHAPTER 7 TUNING ENGINE ............7-1 CHASSIS ..........7-10...
Página 25 All manuals and user guides at all-guides.com CHAPITRE 6 KAPITEL 6 CABÍTULO 6 PARTIE ELEKTRISCHE SISTEMA ANLAGE ELECTRIQUE ELÉCTRICO COMPOSANTS ELECTRIQUES ELEKTRISCHE BAUTEILE COMPONENTES DEL SISTEMA ET SCHEMA DE CABLAGE ..6-1 UND SCHALTPLAN ....6-1 ELÉCTRICO Y DIAGRAMA BLOC CDI CONTROLE PAR KENNFELDGESTEUERTES DE CABLES ........6-1 MICROPROCESSEUR ....6-2...
Página 26: General Information
All manuals and user guides at all-guides.com DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION NOTE: 1 Clutch lever The machine you have purchased may differ 2 Hot starter lever slightly from those shown in the following. 3 “ENGINE STOP” button Designs and specifications are subject to 4 Trip meter change without notice.
Página 27: Información General Descripción
All manuals and user guides at all-guides.com DESCRIPTION FAHRZEUGBESCHREIBUNG DESCRIPCIÓN INFO ALLGEMEINE RENSEIGNEMENTS INFORMACIÓN ANGABEN GENERAUX GENERAL DESCRIPTION FAHRZEUGBESCHREI- DESCRIPCIÓN BUNG 1 Levier d’embrayage 1 Palanca del embrague 2 Levier de démarreur à chaud 2 Palanca de arranque en caliente 1 Kupplungshebel 3 Bouton du coupe-circuit de sécurité...
Página 28: Vehicle Identification Number
There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for posi- tive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
Página 29: Identification De La Machine
En cas de vol du véhicule, la cesionario Yamaha para la identi- police réclamera ces numéros afin ficación positiva del modelo de su de faciliter son identification.
Página 30 All manuals and user guides at all-guides.com IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassem- bly. When washing the machine with high pressured water, cover the parts as fol- lows.
Página 31: Informations Importantes
All manuals and user guides at all-guides.com INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMACIÓN IMPORTANTE INFO INFORMATIONS IMPOR- WICHTIGE INFORMATIO- INFORMACIÓN IMPOR- TANTES TANTE VORBEREITUNG FÜR AUSBAU PREPARATION POUR LA DEPOSE PREPARACIÓN PARA LA UND ZERLEGUNG ET DEMONTAGE EXTRACCIÓN Y EL DESMON- 1.
Página 32 All manuals and user guides at all-guides.com IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1.
Página 33 Yamaha empfohlene Schmier- sustituciones. Para los procesos les huiles/graisses recomman- stoffe verwenden. Fremdfabri- de montaje y ajuste, utilice el dées par Yamaha lors des remon- kate erfüllen häufig nicht die aceite y la grasa recomendados tages et réglages. gestellten Qualitätsanforde- por Yamaha.
Página 34 All manuals and user guides at all-guides.com IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite to the thrust 3 it receives.
Página 35 All manuals and user guides at all-guides.com INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMACIÓN IMPORTANTE INFO SICHERUNGSRINGE CIRCLIPS CIRCLIPS 1. Sicherungsringe vor dem Wie- Avant remontage, tous les circlips Debe inspeccionar cuidadosa- dereinbau sorgfältig überprü- doivent être soigneusement véri- mente todos los circlips antes de fen und bei Beschädigung fiés.
Página 36 All manuals and user guides at all-guides.com CHECKING OF CONNECTION INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times.
Página 37: Verification Des Connexions
All manuals and user guides at all-guides.com VERIFICATION DES CONNEXIONS ANSCHLÜSSE PRÜFEN COMPROBACIÓN DE LAS CONEXIONES INFO VERIFICATION DES ANSCHLÜSSE PRÜFEN COMPROBACIÓN DE Die Steckverbinder auf Oxidation, CONNEXIONS LAS CONEXIONES Rost, Feuchtigkeit usw. prüfen. Traitement des taches, de la rouille, de Compruebe las marchas, el óxido, la 1.
Página 38: Special Tools
All manuals and user guides at all-guides.com SPECIAL TOOLS INFO EC140001 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.
Página 39 Sheave holder YS-1880-A 90890-01701 This tool is used for when loosening or tightening the flywheel magneto securing nut. YU-3112-C, 90890-03112 Yamaha pocket tester YU-3112-C 90890-03112 Use this tool to inspect the coil resistance, output voltage and amperage. YM-33277-A, 90890-03141 Timing light...
Página 40 Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components.  ACC-QUICK-GS-KT Quick gasket ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc. 1 - 9...
Página 41: Outils Speciaux
All manuals and user guides at all-guides.com OUTILS SPECIAUX INFO OUTILS SPECIAUX Les outils spéciaux appropriés sont indispensables pour pouvoir effectuer un assemblage et une mise au point complets et précis. L’utilisation des outils spéciaux corrects permettra d’éviter les endommagements dus à l’emploi d’outils impropres et aux techniques improvisées entraînées par ceux-ci.
Página 42 All manuals and user guides at all-guides.com OUTILS SPECIAUX INFO Numéros de pièce Nom et usage de l’outil Illustration YM-01442, 90890-01442 Outil d’insertion de joint de fourche YM-01442 90890-01442 Cet outil est utilisé pour monter les bagues d’étanchéité de fourche. YS-1880-A, 90890-01701 Clé...
Página 43 90890-06754 Contrôleur d’allumage Ce testeur est nécessaire pour contrôler les composants du système d’allumage. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA bond n˚ 1215 Ce mastic est utilisé sur les plans de joint du carter, etc. 1 - 9...
Página 44 All manuals and user guides at all-guides.com SPEZIALWERKZEUGE INFO SPEZIALWERKZEUGE Die folgenden Spezialwerkzeuge sind für korrekte und vollständige Einstell- und Montagearbeiten unerläßlich. Durch die Verwendung dieser Werkzeuge können Beschädigungen vermieden wer- den, die beim Gebrauch ungeeigneter Hilfsmittel oder improvisierter Techniken entstehen können. Bei der Bestellung von Spezialwerkzeug sollten die im folgenden aufgeführten Bezeichnungen und Teilenummern angegeben werden.
Página 45 All manuals and user guides at all-guides.com SPEZIALWERKZEUGE INFO Teilenummer Werkzeug/Anwendung Abbildung YM-01442, 90890-01442 Gabeldichtring-Treiber YM-01442 90890-01442 Zum Einbau der Gabeldichtringe YS-1880-A, 90890-01701 Kupplungskorb-Halter YS-1880-A 90890-01701 Zum Halten des Kupplungskorbes. YU-3112-C, 90890-03112 Taschen-Multimeter YU-3112-C 90890-03112 Zur Prüfung und Messung der elektrischen Systeme YM-33277-A, 90890-03141 Stroboskoplampe YM-33277-A 90890-03141...
Página 46 INFO Teilenummer Werkzeug/Anwendung Abbildung YM-04142, 90890-04142 Rotorzieher YM-04142 90890-04142 Zum Ausbau des Schwungradmagnetzünder-Rotors YM-34487 Zündfunkenstreckentester YM-34487 90890-06754 90890-06754 Zündprüfer Zur Überprüfung der Zündanlage ® ACC-QUICK-GS-KT Quick gasket ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA-Dichtmasse Nr. 1215 Zum Abdichten der Kurbelgehäuse-Paßflächen 1 - 9...
Página 47: Yu-3097, 90890-01252 Yu
All manuals and user guides at all-guides.com HERRAMIENTAS ESPECIALES INFO HERRAMIENTAS ESPECIALES Las herramientas especiales apropiadas son indispensables para realizar un montaje y puesta a punto precisos. El empleo de herramientas especiales correctas ayudará a evitar daños provocados por el uso de herramientas inadecuadas o métodos inapropiados.
Página 48: Ys-1880-A, 90890-01701
All manuals and user guides at all-guides.com HERRAMIENTAS ESPECIALES INFO Número de pieza Nombre de la herramienta/Función Ilustración YM-01442, 90890-01442 Montador de retenes de la horquilla YM-01442 90890-01442 Esta herramienta se utiliza cuando se instala el retén de aceite de la horquilla. YS-1880-A, 90890-01701 Soporte de roldana YS-1880-A...
Página 49 Comprobador de encendido Este instrumento se utiliza para comprobar los componen- tes del sistema de encendido. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 Adhesivo YAMAHA Nº 1215 Este sellador (adhesivo) se utiliza para las superficies del cárter engranadas, etc. 1 - 9...
Página 50: Main Switch
All manuals and user guides at all-guides.com CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch 1 is equipped with an indica- tor light 2 to avoid forgetting to turn it off.
Página 51: Fonctions Des Commandes
All manuals and user guides at all-guides.com FONCTIONS DES COMMANDES STEUERFUNKTIONEN FUNCIONES DE CONTROL INFO FONCTIONS DES COM- STEUERFUNKTIONEN FUNCIONES DE ZÜNDSCHALTER MANDES CONTROL Funktionen einzelnen COUPE-CIRCUIT DU MOTEUR INTERRUPTOR PRINCIPAL Schalterpositionen sind wie folgt: Les fonctions des différentes positions Las funciones de las respectivas posicio- du coupe-circuit sont les suivantes : nes del interruptor son como se indica a...
Página 52 All manuals and user guides at all-guides.com CONTROL FUNCTIONS INFO EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disen- gage the clutch, and release the lever to engage the clutch.
Página 53 All manuals and user guides at all-guides.com FONCTIONS DES COMMANDES STEUERFUNKTIONEN FUNCIONES DE CONTROL INFO KUPPLUNGSHEBEL LEVIER D’EMBRAYAGE PALANCA DEL EMBRAGUE Le levier d’embrayage 1 est situé sur le Der Kupplungshebel 1 befindet sich La palanca del embrague 1 está situada guidon gauche et permet d’embrayer ou auf der linken Seite des Lenkers und en el manillar izquierdo;...
Página 54: Rear Brake Pedal
All manuals and user guides at all-guides.com CONTROL FUNCTIONS INFO EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel.
Página 55 All manuals and user guides at all-guides.com FONCTIONS DES COMMANDES STEUERFUNKTIONEN FUNCIONES DE CONTROL INFO FUSSBREMSHEBEL PEDALE DE FREIN ARRIERE PALANCA DEL FRENO TRASERO La pédale de frein arrière 1 se trouve du Der Fußbremshebel 1 zur Betäti- La palanca del freno trasero 1 está côté...
Página 56: Sidestand
All manuals and user guides at all-guides.com CONTROL FUNCTIONS INFO 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. Hold up the sidestand before starting out. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing...
Página 57 All manuals and user guides at all-guides.com FONCTIONS DES COMMANDES STEUERFUNKTIONEN FUNCIONES DE CONTROL INFO SEITENSTÄNDER BÉQUILLE LATÉRALE SOPORTE LATERAL Cette béquille latérale 1 est conçue Der Seitenständer 1 ist nur zum El soporte lateral 1 se utiliza para apo- exlusivement pour ce véhicule afin de le Tragen Maschinengewichts...
Página 58 All manuals and user guides at all-guides.com FUEL INFO FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Recommended fuel: Except for ZA: Premium unleaded gasoline only with a research octane number of 95 or higher.
Página 59: Essence
All manuals and user guides at all-guides.com ESSENCE KRAFTSTOFF COMBUSTIBLE INFO ESSENCE KRAFTSTOFF COMBUSTIBLE Ausschließlich empfohlenen Toujours utiliser l’essence recommandée Utilice siempre el combustible recomen- Kraftstoff verwenden. Für Rennen fri- décrite ci-dessous. D’autre part, s’assu- dado que se indica a continuación. Ade- schen Kraftstoff verwenden.
Página 60: Air Filter Maintenance
All manuals and user guides at all-guides.com STARTING AND BREAK-IN INFO STARTING AND BREAK-IN WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area.
Página 61: Mise En Marche Et Rodage
All manuals and user guides at all-guides.com MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN ARRANQUE Y RODAJE INFO MISE EN MARCHE ET ANLASSEN UND EINFAH- ARRANQUE Y RODAJE RODAGE ADVERTENCIA WARNUNG Nunca arranque ni utilice el motor en AVERTISSEMENT una zona cerrada.
Página 62 All manuals and user guides at all-guides.com STARTING AND BREAK-IN INFO NOTE: If the engine fails to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery.
Página 63 All manuals and user guides at all-guides.com MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN ARRANQUE Y RODAJE INFO HINWEIS: N.B.: NOTA: Si le moteur ne démarre pas avec le com- Wenn der Motor beim Drücken des Si el motor no arrancase presionando el mutateur de démarrage, relâcher le com- Startschalters nicht anspringt, den interruptor de arranque, suelte el inte-...
Página 64: Starting A Warm Engine
All manuals and user guides at all-guides.com STARTING AND BREAK-IN INFO STARTING A WARM ENGINE Do not operate the cold starter knob and throt- tle. Pull the hot starter lever 1 and start the engine by pushing the start switch or by kick- ing the kickstarter forcefully with a firm stroke.
Página 65 All manuals and user guides at all-guides.com MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN ARRANQUE Y RODAJE INFO STARTEN MIT WARMEM MOTOR MISE EN MARCHE D’UN ARRANQUE DE UN MOTOR EN Zum Anlassen des warmen Motors MOTEUR CHAUD CALIENTE Ne pas activer le bouton de démarrage à...
Página 66 All manuals and user guides at all-guides.com STARTING AND BREAK-IN INFO BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “ENGINE STOP”...
Página 67 All manuals and user guides at all-guides.com MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN ARRANQUE Y RODAJE INFO EINFAHRVORSCHRIFTEN PROCEDURE DE RODAGE PROCEDIMIENTOS DE RODAJE 1. Vor dem Anlassen des Motors Avant de mettre le moteur en Antes de arrancar el motor, llene marche, faire le plein d’essence.
Página 68: Torque-Check Points
All manuals and user guides at all-guides.com TORQUE-CHECK POINTS INFO TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and 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 shaft to...
Página 69: Points De Verification De Couple De Serrage
All manuals and user guides at all-guides.com POINTS DE VERIFICATION DE COUPLE DE SERRAGE INFO POINTS DE VERIFICATION DE COUPLE DE SERRAGE Construction du cadre Du cadre au cadre arrière Combinaison de selle Du réservoir à essence au cadre et de réservoir Système d’échappement Silencieux à...
Página 70 All manuals and user guides at all-guides.com ANZUGSMOMENTE KONTROLLIEREN INFO ANZUGSMOMENTE KONTROLLIEREN Rahmen Hauptrahmen und Rahmenhinterteil Sitzbank und Kraftstofftank Kraftstofftank und Rahmen Auspuff-System Schalldämpfer an hinteren Rahmen Motoraufhängung Rahmen und Motor Motorbügel und Motor Motorbügel und Rahmen Lenkung Lenkkopf und Lenkkopf und Teleskopgabel Lenkkopf und obere Gabelbrücke Lenker...
Página 71 All manuals and user guides at all-guides.com PUNTOS DE COMPROBACIÓN DE LA TORSIÓN INFO PUNTOS DE COMPROBACIÓN DE LA TORSIÓN Construcción del bastidor Del bastidor al bastidor trasero Asiento y depósito combinado Del depósito de combustible al bastidor Sistema de escape Del silenciador al bastidor trasero Montura del motor Del bastidor al motor...
Página 72 All manuals and user guides at all-guides.com CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good 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.
Página 73: Nettoyage Et Rangement
All manuals and user guides at all-guides.com NETTOYAGE ET RANGEMENT REINIGUNG UND STILLEGUNG LIMPIEZA Y ALMACENAMIENTO INFO NETTOYAGE ET RANGE- REINIGUNG UND STILLE- LIMPIEZA Y ALMACE- GUNG MENT NAMIENTO REINIGUNG NETTOYAGE LIMPIEZA Eine regelmäßige, gründliche Un nettoyage fréquent de la machine La frecuente limpieza de su vehículo Wäsche sorgt nicht nur für gutes améliorera son aspect, maintiendra ses...
Página 74 All manuals and user guides at all-guides.com CLEANING AND STORAGE INFO 8. Automotive wax may be applied to all painted or chromed surfaces. Avoid com- bination cleaner-waxes, as they may con- tain abrasives. 9. After completing the above, start the engine and allow it to idle for several min- utes.
Página 75 All manuals and user guides at all-guides.com NETTOYAGE ET RANGEMENT REINIGUNG UND STILLEGUNG LIMPIEZA Y ALMACENAMIENTO INFO 8. Lack- und Chromflächen kön- Un encaustique pour automobile Puede aplicar cera de automotor a nen mit Autowachs poliert peut être appliqué sur toutes les todas las superficies pintadas o werden.
Página 76: General Specifications
All manuals and user guides at all-guides.com SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: WR450FS (USA) WR450F (EUROPE) WR450F(S) (CDN, AUS, NZ, ZA) Model code number: 5TJ5 (USA) 5TJ6 (EUROPE) 5TJ7 (CDN, AUS, NZ, ZA) Dimensions: Overall length 2,171 mm (85.5 in) Overall width 827 mm (32.6 in)
Página 77 All manuals and user guides at all-guides.com SPEC GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 1.0 L (0.88 Imp qt, 1.06 US qt) With oil filter replacement 1.1 L (0.97 Imp qt, 1.16 US qt) Total amount 1.2 L (1.06 Imp qt, 1.27 US qt) Coolant capacity (including all routes): 1.6 L (1.41 Imp qt, 1.69 US qt) Air filter:...
Página 78 All manuals and user guides at all-guides.com SPEC GENERAL SPECIFICATIONS Brake: Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm (link type monocross suspension) Shock absorber: Front shock absorber Coil spring/oil damper...
Página 79 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 95.00 ~ 95.01 mm ---- (3.7402 ~ 3.7406 in) Out of round limit ---- 0.05 mm (0.002 in)
Página 80: Maintenance Specifications
All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cam chain: Cam chain type/No. of links 98XRH2010-118M/118 ---- Cam chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.10 ~ 0.15 mm ---- (0.0039 ~ 0.0059 in) 0.20 ~ 0.25 mm...
Página 81 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Valve spring: Free length 37.03 mm (1.46 in) 36.03 mm (1.42 in) 37.68 mm (1.48 in) 36.68 mm (1.44 in) Set length (valve closed) 27.87 mm (1.10 in) ---- 27.38 mm (1.08 in) ----...
Página 82 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston rings: Top ring: Type Barrel ---- Dimensions (B × T) 1.2 × 3.5 mm (0.05 × 0.14 in) ---- End gap (installed) 0.20 ~ 0.30 mm 0.55 mm (0.008 ~ 0.012 in) (0.022 in)
Página 83 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness 2.92 ~ 3.08 mm 2.8 mm (0.115 ~ 0.121 in) (0.110 in) Quantity ---- Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- Quantity ----...
Página 84 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance “A” 0.12 mm or less 0.20 mm (0.0047 in or less) (0.008 in) Tip clearance “B”...
Página 85: Lubrication Chart
All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Lubrication chart: Pressure feed Oil tank Splashed scavenge Camshaft Cylinder head Valve lifter Piston Transmission gears Piston pin Main axle Oil filter Crank pin Drive axle Check ball Oil pump rotor 1 Oil pump rotor 2 Oil strainer...
Página 86 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M10S × 1.0 Spark plug M6 × 1.0 Camshaft cap M12 × 1.0 Cylinder head blind plug screw M6 × 1.0 Cylinder head (stud bolt) M8 ×...
Página 87 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M6 × 1.0 Oil check bolt Oil hose clamp – M6 × 1.0 Clutch cover M6 × 1.0 Crankcase cover (right) M6 ×...
Página 88 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS EC212201 CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN EUROPE AUS, NZ, ZA 300 mm (11.8 in) ← ← Front fork travel 460 mm (18.1 in) ←...
Página 89 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Wheel: Front wheel type Spoke wheel ---- Rear wheel type Spoke wheel ---- 21 × 1.60/Aluminum Front rim size/material ---- 18 × 2.15/Aluminum Rear rim size/material ---- Rim runout limit: Radial ----...
Página 90 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Handle crown and outer tube M8 × 1.25 Under bracket and outer tube M24 × 1.0 Handle crown and steering shaft 14.5 M8 ×...
Página 91 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M20 × 1.5 Rear wheel axle and nut 12.5 M8 × 1.25 Driven sprocket and wheel hub Nipple (spoke) –...
Página 92 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M5 × 0.8 Meter cable holder and protector M8 × 1.25 Headlight stay (lower) and under bracket M6 × 1.0 Headlight body and headlight unit M6 ×...
Página 93 Advancer type Electrical ---- C.D.I.: 248 ~ 372 Ω at 20 ˚C (68 ˚F) Pickup coil resistance (color) ---- (White – Red) CDI unit-model/manufacturer 5TJ50/YAMAHA (For USA) ---- 5TJ60/YAMAHA ---- (Except for USA) Ignition coil: Model/manufacturer 5TA-10/DENSO ---- Minimum spark gap 6 mm (0.24 in)
Página 94 All manuals and user guides at all-guides.com SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Starter relay: Model/manufacturer 2768090-A/JIDECO ---- Amperage rating 180 A ---- 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) Coil winding resistance ---- Starting circuit cut-off relay: Model/manufacturer ACM33221 M06/MATSUSHITA ----...
Página 95: General Torque Specifications
All manuals and user guides at all-guides.com GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book.
Página 96: Caracteristiques Generales
All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES GENERALES CARACTERISTIQUES CARACTERISTIQUES GENERALES Nom de modèle: WR450FS (USA) WR450F (EUROPE) WR450F(S) (CDN, AUS, NZ, ZA) Numéro de code de modèle: 5TJ5 (USA) 5TJ6 (EUROPE) 5TJ7 (CDN, AUS, NZ, ZA) Dimensions: Longueur hors-tout 2.171 mm (85,5 in) Largeur hors-tout...
Página 97 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES GENERALES Quantité d’huile: Huile de moteur Vidange périodique 1,0 L (0,88 Imp qt, 1,06 US qt) Avec remplacement du ﬁltre à huile 1,1 L (0,97 Imp qt, 1,16 US qt) Quantité totale 1,2 L (1,06 Imp qt, 1,27 US qt) Capacité...
Página 98 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES GENERALES Freins: Type de frein avant Frein à simple disque Commande Main droite Type de frein arrière Frein à simple disque Commande Pied droit Suspension: Suspension avant Fourche télescopique Suspension arrière Bras oscillant (monocross de type biellette) Amortisseurs: Amortisseur avant...
Página 99: Caracteristiques D'entretien
All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN CARACTERISTIQUES D’ENTRETIEN MOTEUR Article Standard Limite Culasse: Limite de déformation ---- 0,05 mm (0,002 in) Cylindre: Alésage 95,00 à 95,01 mm ---- (3,7402 à 3,7406 in) Limite d’ovalisation ---- 0,05 mm (0,002 in) Arbre à...
Página 100 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Chaîne de distribution: Type de chaîne de distribution/nbre de maillons 98XRH2010-118M/118 ---- Méthode de réglage de la chaîne de distribution Automatique ---- Soupape, siège de soupape, guide de soupape: Jeu de soupape (à...
Página 101 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Ressort de soupape: Longueur libre 37,03 mm (1,46 in) 36,03 mm (1,42 in) 37,68 mm (1,48 in) 36,68 mm (1,44 in) Longueur monté (soupape fermée) AD 27,87 mm (1,10 in) ---- 27,38 mm (1,08 in) ----...
Página 102 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Segment: Segment de feu: Type Cylindrique ---- Dimensions (B × T) 1,2 × 3,5 mm (0,05 × 0,14 in) ---- Ecartement des becs (monté) 0,20 à 0,30 mm 0,55 mm (0,008 à...
Página 103 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Embrayage: Epaisseur de disque de friction 2,92 à 3,08 mm (0,115 à 0,121 in) 2,8 mm (0,110 in) Quantité ---- Epaisseur de disque d’embrayage 1,1 à 1,3 mm (0,043 à 0,051 in) ---- Quantité...
Página 104 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Système de graissage: Type de ﬁltre à huile Type de papier ---- Type de pompe à huile Trochoïde ---- Jeu en bout “A” 0,12 mm ou moins 0,20 mm (0,0047 in ou moins) (0,008 in)
Página 105 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Diagramme de graissage: Réservoir d’huile Graissage sous pression Barbotage Arbre à cames Culasse Poussoir de soupape Piston Engrenage de la transmission Axe de piston Arbre primaire Maneton de bielle Filtre à...
Página 106 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb M10S × 1,0 Bougie M6 × 1,0 Chapeau d’arbre à cames M12 × 1,0 Vis de faux bouchon de culasse M6 ×...
Página 107 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb M6 × 1,0 Boulon de contrôle d’huile Bride du flexible d’huile — M6 × 1,0 Couvercle d’embrayage M6 × 1,0 Couvercle de carter (droit) M6 ×...
Página 108: Partie-Cycle
All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN PARTIE-CYCLE Article Standard Limite Direction: Type de roulement de direction Roulement à rouleaux conique ---- Suspension avant: USA, CDN EUROPE AUS, NZ, ZA ← ← Débattement de fourche avant 300 mm (11,8 in) ←...
Página 109 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Roue: Type de roue avant Roue à rayons ---- Type de roue arrière Roue à rayons ---- 21 × 1,60/aluminum Taille/matériau de jante avant ---- 18 × 2,15/aluminum Taille/matériau de jante arrière ---- Limite de voile de jante:...
Página 110 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb M8 × 1,25 Couronne de guidon et fourreau M8 × 1,25 Etrier inférieur et fourreau M24 × 1,0 Couronne de guidon et colonne de direction 14,5 M8 ×...
Página 111 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb M20 × 1,5 Axe de roue arrière et écrou 12,5 M8 × 1,25 Pignon mené et moyeu de roue Ecrou de rayon —...
Página 112 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb M5 × 0,8 Support et protection du câble de compteur M8 × 1,25 Montant de phare (inférieur) et support inférieur M6 ×...
Página 113: Partie Electrique
Electrique ---- CDI: 248 à 372 Ω à 20 ˚C (68 ˚F) Résistance de bobine d’excitation ---- (couleur) (blanc – rouge) Modèle/fabricant du bloc CDI 5TJ50/YAMAHA ---- (Pour les USA) 5TJ60/YAMAHA ---- (Excepté pour les USA) Bobine d’allumage: Modèle/fabricant 5TA-10/DENSO ---- Longueur minimum d’étincelle...
Página 114 All manuals and user guides at all-guides.com SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Relais du démarreur: Modèle/fabricant 2768090-A/JIDECO ---- Nombre d’ampères 180 A ---- 4,2 à 4,6 Ω à 20 ˚C (68 ˚F) Résistance des spirales de la bobine ---- Relais du coupe-circuit de démarrage: Modèle/fabricant ACM33221 M06/MATSUSHITA...
Página 115: Caracteristiques Generales De Couple
All manuals and user guides at all-guides.com CARACTERISTIQUES GENERALES DE COUPLE/ SPEC DEFINITION DES UNITES CARACTERISTIQUES GENERALES DE COUPLE Ce tableau spécifie les couples de serrage des atta- ches standard avec filetage à pas I.S.O. standard. Les spécifications de couple pour les composants ou ensembles spéciaux sont indiquées dans les sec- tions appropriées de ce manuel.
Página 116: Technische Daten
All manuals and user guides at all-guides.com SPEC ALLGEMEINE TECHNISCHE DATEN TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN Modellname: WR450FS (USA) WR450F (EUROPA) WR450F(S) (CDN, AUS, NZ, ZA) Modellcode: 5TJ5 (USA) 5TJ6 (EUROPA) 5TJ7 (CDN, AUS, NZ, ZA) Abmessungen: Gesamtlänge 2.171 mm (85,5 in) Gesamtbreite 827 mm (32,6 in) Gesamthöhe...
Página 117: Allgemeine Technische Daten
All manuals and user guides at all-guides.com SPEC ALLGEMEINE TECHNISCHE DATEN Ölmenge: Füllmenge Ölwechsel ohne Filterwechsel 1,0 L (0,88 Imp qt, 1,06 US qt) Ölwechsel mit Filterwechsel 1,1 L (0,97 Imp qt, 1,16 US qt) Gesamtmenge 1,2 L (1,06 Imp qt, 1,27 US qt) Kühlsystem-Fassungsvermögen 1,6 L (1,41 Imp qt, 1,69 US qt) (Gesamtmenge):...
Página 118 All manuals and user guides at all-guides.com SPEC ALLGEMEINE TECHNISCHE DATEN Bremsanlage: vorn Bauart Einscheibenbremse Betätigung Handbremshebel (rechts) hinten Bauart Einscheibenbremse Betätigung Fußbremshebel (rechts) Radaufhängung: vorn Teleskopgabel hinten Monocross-Schwinge Federelemente: vorn hydraulisch gedämpfte Teleskopgabel mit Spi- ralfeder hinten Federbein mit gasdruckunterstütztem Stoß- dämpfer und Spiralfeder Federweg: vorn...
Página 119 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN WARTUNGSDATEN MOTOR Bezeichnung Speziﬁkation Grenzwert Zylinderkopf: Max. Verzug ---- 0,05 mm (0,002 in) Zylinder: Bohrungsdurchmesser 95,00–95,01 mm ---- (3,7402–3,7406 in) Max. Ovalität ---- 0,05 mm (0,002 in) Nockenwelle: Antrieb Steuerkette (links) ---- Nockenwellenlager-Durchmesser 22,000–22,021 mm...
Página 120 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Steuerkette: Typ/Gliederzahl 98XRH2010-118M/118 ---- Kettenspannung automatisch ---- Ventile, Ventilsitze, Ventilführungen: Ventilspiel (kalt) Einlaß 0,10–0,15 mm ---- (0,0039–0,0059 in) Auslaß 0,20–0,25 mm ---- (0,0079–0,0098 in) Ventilabmessungen Ventilsitzbreite Ventiltellerstärke Ventiltellerdurchmesser Ventilkegelbreite Ventilteller-Durchmesser Ventilteller-Breite...
Página 121 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Ventilfeder: Ungespannte Länge Einlaß 37,03 mm (1,46 in) 36,03 mm (1,42 in) Auslaß 37,68 mm (1,48 in) 36,68 mm (1,44 in) Einbaulänge (Ventil geschlossen) Einlaß 27,87 mm (1,10 in) ---- Auslaß...
Página 122 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Kolbenringe: 1. Kompressionsring (Topring) Ausführung abgerundet ---- Abmessungen (B × T) 1,2 × 3,5 mm (0,05 × 0,14 in) ---- Stoßspiel (eingebaut) 0,20–0,30 mm (0,008–0,012 in) 0,55 mm (0,022 in) Ringnutspiel (eingebaut) 0,030–0,065 mm...
Página 123 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Kupplung: Reibscheiben Stärke 2,92–3,08 mm (0,115–0,121 in) 2,8 mm (0,110 in) Anzahl ---- Kupplungsscheiben Stärke 1,1–1,3 mm (0,043–0,051 in) ---- Anzahl ---- Verzug ---- 0,1 mm (0,004 in) Kupplungsfeder ungesp.
Página 124 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Schmiersystem: Ölﬁlter Papiertyp ---- Ölpumpe Rotorpumpe ---- Radialspiel “A” 0,12 mm oder weniger 0,20 mm (0,0047 in oder weniger) (0,008 in) Radialspiel “B” 0,09–0,17 mm 0,24 mm (0,0035–0,0067 in) (0,009 in) Axialspiel 0,03–0,10 mm...
Página 125 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Ölkreislauf-Schaubild Öltank Druckumlaufschmierung Spritzschmierung Nockenwelle Zylinderkopf Tassenstößel Kolben Getriebezahnräder Kolbenbolzen Getriebe- Eingangswelle Kurbelwellenzapfen Ölfilter Getriebe- Ausgangswelle Rückschlagventil Ölpumpenrotor 1 Ölpumpenrotor 2 Ölsieb Ölwanne 2 - 10...
Página 126 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Anzugs-moment Bauteil Gewinde Anz. m·kg ft·lb M10S × 1,0 Zündkerze M6 × 1,0 Zündkerzenstecker M12 × 1,0 Zylinderkopf-Blindstopfenschraube M6 × 1,0 Zylinderkopf (Stiftschraube) M8 × 1,25 M10 × 1,25 (Schraube) Siehe HINWEIS.* M6 ×...
Página 127 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Anzugs-moment Bauteil Gewinde Anz. m·kg ft·lb M6 × 1,0 Ölprüfschraube Ölschlauchschelle — M6 × 1,0 Kupplungsdeckel M6 × 1,0 Kurbelgehäusedeckel (rechts) M6 × 1,0 Kurbelgehäusedeckel (links) M6 × 1,0 Leerlaufgetriebedeckel (Startermotor) M6 ×...
Página 128 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN FAHRWERKL Bauteil Speziﬁkation Grenzwert Lenkung: Lenkkopflager Kegelrollenlager ---- Federelement vorn: USA, CDN EUROPA AUS, NZ, ZA 300 mm (11,8 in) ← ← Federweg 460 mm (18,1 in) ← ← Gabelfeder, ungespannte Länge Standard-Federrate K = 4,51 N/mm K = 4,12 N/mm...
Página 129 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bauteil Speziﬁkation Grenzwert Räder: Bauart: Vorderrad Speichenrad ---- Hinterrad Speichenrad ---- Felgendimension/-material 21 × 1,60/Aluminium Vorderrad ---- 18 × 2,15/Aluminium Hinterrad ---- Max. Felgenschlag Höhenschlag ---- 2,0 mm (0,08 in) Seitenschlag ---- 2,0 mm (0,08 in)
Página 130 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg ft·lb M8 × 1,25 Obere Gabelbrücke und Standrohr M8 × 1,25 Untere Gabelbrücke und Standrohr M24 × 1,0 Obere Gabelbrücke und Lenkkopf 14,5 M8 × 1,25 Lenkerhalterung (oben) M28 ×...
Página 131 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg ft·lb M20 × 1,5 Hinterachse und Mutter 12,5 M8 × 1,25 Antriebskettenrad und Radnabe Speichen-Nippel — M6 × 1,0 Bremsscheiben-Abdeckung und Bremssattel hinten M6 × 1,0 Bremssattel-Schutz und Bremssattel hinten M8 ×...
Página 132 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg ft·lb M5 × 0,8 Instrumentenkabelhalter und Schutz M8 × 1,25 Scheinwerferstrebe (unten) und Unterbügel M6 × 1,0 Scheinwerfergehäuse und Scheinwerferein- heit M6 × 1,0 Scheinwerferhalterung (links und rechts) M6 ×...
Página 133 Zündsystem: Zündversteller elektrisch ---- CDI: 248–372 Ω bei 20 ˚C (68 ˚F) Impulsgeber-Widerstand (Farbe) ---- (weiß – rot) CDI-Zündbox: Typ (Hersteller) 5TJ50/YAMAHA (Nur USA) ---- 5TJ60/YAMAHA (Nicht USA) ---- Zündspule: Typ (Hersteller) 5TA-10/DENSO ---- Min. Zündfunkenstrecke 6 mm (0,24 in) ---- 0,08–0,10 Ω...
Página 134 All manuals and user guides at all-guides.com SPEC WARTUNGSDATEN Bauteil Speziﬁkation Grenzwert Starterrelais: Modell/Hersteller 2768090-A/JIDECO ---- Stromstärke 180 A ---- 4,2–4,6 Ω bei 20 ˚C (68 ˚F) Spulenwicklungswiderstand ---- Starterkreis-Unterbrecherrelais: Modell/Hersteller ACM33221 M06/MATSUSHITA ---- 75,69–92,51 Ω bei 20 ˚C (68 ˚F) Spulenwicklungswiderstand ---- Sicherung (Stärke ×...
Página 135: Allgemeine Anzugsmomente/ Einheiten Spec Allgemeine Anzugsmomente
All manuals and user guides at all-guides.com ALLGEMEINE ANZUGSMOMENTE/ SPEC EINHEITEN ALLGEMEINE ANZUGSMOMENTE Aus der folgenden Tabelle sind die Anzugsmo- mente für normale Schraubverbindungen mit ISO-Normgewinde ersichtlich. Anzugsmomente für spezielle Verschraubungen und Bauteile wer- den in jedem Abschnitt dieser Anleitung geson- dert aufgeführt.
Página 136 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES GENERALES ESPECIFICACIONES ESPECIFICACIONES GENERALES Nombre del modelo: WR450FS (USA) WR450F (EUROPE) WR450F(S) (CDN, AUS, NZ, ZA) Número del código del modelo: 5TJ5 (USA) 5TJ6 (EUROPE) 5TJ7 (CDN, AUS, NZ, ZA) Dimensiones: Longitud total 2.171 mm (85,5 in) Anchura total...
Página 137: Especificaciones Generales
All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES GENERALES Capacidad de aceite: Aceite de motor Cambio de aceite periódico 1,0 L (0,88 Imp qt, 1,06 US qt) Con sustitución del filtro de aceite 1,1 L (0,97 Imp qt, 1,16 US qt) Cantidad total 1,2 L (1,06 Imp qt, 1,27 US qt) Capacidad de refrigerante...
Página 138 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES GENERALES Neumático: Tipo Con cámara Tamaño (delantero) 80/100-21 51M (USA, CDN, ZA) 90/90-21 54R (EUROPE, AUS, NZ) Tamaño (trasero) 110/100-18 64M (USA, CDN, ZA) 130/90-18 69R (EUROPE, AUS, NZ) Presión del neumático (delantero y trasero) 100 kPa (1,0 kgf/cm , 15 psi) Freno:...
Página 139 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO ESPECIFICACIONES DE MANTENIMIENTO MOTOR Ítem Estándar Límite Culata: Límite de alabeo ---- 0,05 mm (0,002 in) Cilindro: Tamaño del diámetro 95,00 ~ 95,01 mm ---- (3,7402 ~ 3,7406 in) Límite de ovalización ---- 0,05 mm...
Página 140: Especificaciones De Mantenimiento
All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Ítem Estándar Límite Cadena de la leva: Tipo de cadena de la leva/N˚ de eslabones 98XRH2010-118M/118 ---- Método de ajuste de la cadena de la leva Automático ---- Válvula, asiento de la válvula, guía de válvula: Juego de la válvula (en frío) ADMISIÓN 0,10 ~ 0,15 mm...
Página 141 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Ítem Estándar Límite Muelles de la válvula: Longitud libre ADMISIÓN 37,03 mm (1,46 in) 36,03 mm (1,42 in) ESCAPE 37,68 mm (1,48 in) 36,68 mm (1,44 in) Longitud comprimida (válvula cerrada) ADMISIÓN 27,87 mm (1,10 in)
Página 142 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Ítem Estándar Límite Aros del pistón: Aro superior: Tipo Barril ---- Dimensiones (B × T) 1,2 × 3,5 mm (0,05 × 0,14 in) ---- Separación entre puntas (montado) 0,20 ~ 0,30 mm 0,55 mm (0,008 ~ 0,012 in) (0,022 in)
Página 143 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Ítem Estándar Límite Embrague: Grosor del plato de fricción 2,92 ~ 3,08 mm (0,115 ~ 0,121 in) 2,8 mm (0,110 in) Cantidad ---- Grosor del disco de embrague 1,1 ~ 1,3 mm (0,043 ~ 0,051 in) ---- Cantidad ----...
Página 144 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Ítem Estándar Límite Sistema de lubricación: Tipo de filtro de aceite Tipo papel ---- Tipo de bomba de aceite Tipo trocoidal ---- Juego axial “A” 0,12 mm o menos 0,20 mm (0,0047 in o menos) (0,008 in)
Página 145 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Ítem Estándar Tabla de lubricación: Depósito de aceite Alimentación a presión Eliminación de salpicaduras Árbol de levas Culata Empujador de válvula Pistón Engranajes de transmisión Bulón del pistón Eje principal Bulón de levas Filtro de aceite Eje de transmisión...
Página 146 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Par de apriete Tamaño de la Pieza a apretar Cant. rosca m·kg ft·lb M10S × 1,0 Bujía M6 × 1,0 Tapa del árbol de levas M12 × 1,0 Tornillo del tapón ciego de la culata M6 ×...
Página 147 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Par de apriete Tamaño de la Pieza a apretar Cant. rosca m·kg ft·lb M6 × 1,0 Perno de comprobación del aceite Abrazadera del tubo de aceite — M6 × 1,0 Cubierta del embrague M6 ×...
Página 148 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO CHASIS Ítem Estándar Límite Sistema de dirección: Tipo de cojinete de dirección Cojinete de rodillos cónicos ---- Suspensión delantera: USA, CDN EUROPE AUS, NZ, ZA ← ← Recorrido de la horquilla delantera 300 mm (11,8 in) ←...
Página 149 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Ítem Estándar Límite Rueda: Tipo de rueda delantera Radio de la rueda ---- Tipo de rueda trasera Radio de la rueda ---- 21 × 1,60/Aluminio Tamaño de la llanta delantera/material ---- 18 ×...
Página 150 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Par de apriete Tamaño de la Pieza a apretar Cant. rosca m·kg ft·lb M8 × 1,25 Tija superior del manillar y tubo exterior M8 × 1,25 Ménsula inferior y tubo exterior M24 ×...
Página 151 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Par de apriete Tamaño de la Pieza a apretar Cant. rosca m·kg ft·lb M20 × 1,5 Eje de la rueda trasera y tuerca 12,5 M8 × 1,25 Piñón de transmisión y rodete de la rueda Engrasador (radio) —...
Página 152 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Par de apriete Tamaño de la Pieza a apretar Cant. rosca m·kg ft·lb M5 × 0,8 Soporte del cable del medidor y protector M8 × 1,25 Soporte del faro (inferior) y ménsula inferior M6 ×...
Página 153: Sistema Eléctrico
CDI: 248 ~ 372 Ω a 20 ˚C (68 ˚F) Resistencia de la bobina de aceleración rápida ---- (color) (Blanco – Rojo) Modelo de la unidad CDI/fabricante 5TJ50/YAMAHA ---- (Para USA) 5TJ60/YAMAHA ---- (Excepto para USA) Bobina de encendido: Modelo/fabricante...
Página 154 All manuals and user guides at all-guides.com SPEC ESPECIFICACIONES DE MANTENIMIENTO Ítem Estándar Límite Relé del arrancador: Modelo/fabricante 2768090-A/JIDECO ---- Amperaje nominal 180 A ---- 4,2 ~ 4,6 Ω a 20 ˚C (68 ˚F) Resistencia del bobinado ---- Relé interruptor del circuito de encendido: Modelo/fabricante ACM33221 M06/MATSUSHITA ----...
Página 155: Definición De Unidades
All manuals and user guides at all-guides.com ESPECIFICACIONES DE APRIETE GENERALES/ SPEC DEFINICIÓN DE UNIDADES ESPECIFICACIONES DE APRIETE GENERALES Esta tabla especifica el apriete de los elementos de fijación provistos de roscas I.S.O. estándar. Las especificaciones de apriete para los componentes o conjuntos especiales se incluyen en las secciones correspondientes del manual.
Página 156: Lubrication Diagrams
All manuals and user guides at all-guides.com SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 Intake camshaft 3 Exhaust camshaft 4 Oil cleaner element 5 Oil pump 6 Main axle 7 Drive axle D - D A - A 2 - 21...
Página 157: Schemas De Graissage
All manuals and user guides at all-guides.com SCHEMAS DE GRAISSAGE SCHMIERSYSTEM-SCHAUBILDER SPEC DIAGRAMAS DE LUBRICACIÓN SCHEMAS DE GRAIS- SCHMIERSYSTEM- DIAGRAMAS DE LUBRI- SCHAUBILDER SAGE CACIÓN 1 Ölzufuhrleitung 1 Tuyau d’arrivée d’huile 1 Tubo de distribución del aceite 2 Einlaß-Nockenwelle 2 Arbre à cames d’admission 2 Admisión del árbol de levas 3 Auslaß-Nockenwelle 3 Arbre à...
Página 158 All manuals and user guides at all-guides.com SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Connecting rod 3 Oil cleaner element 4 Crankshaft 5 Main axle 6 Drive axle 7 Oil delivery pipe 2 - 22...
Página 159 All manuals and user guides at all-guides.com SCHEMAS DE GRAISSAGE SCHMIERSYSTEM-SCHAUBILDER SPEC DIAGRAMAS DE LUBRICACIÓN 1 Arbre à cames 1 Nockenwelle 1 Árbol de levas 2 Bielle 2 Pleuel 2 Biela 3 Element du filtre à air 3 Ölfiltereinsatz 3 Elemento del filtro de aceite 4 Vilebrequin 4 Kurbelwelle 4 Arbol de levas...
Página 160: Cable Routing Diagram
All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM Ç Fasten the wire harness, recti- 1 Fuel tank breather hose G Brake hose 2 Clamp H Hose guide fier/regulator lead, coolant res- 3 Diode I Carburetor breather hose ervoir hose and hot starter cable J Overflow hose...
Página 161: Cheminement Des Cables
All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC DIAGRAMA DE RUTA DE CABLES CHEMINEMENT KABELFÜHRUNG DIAGRAMA DE RUTA DE CABLES CABLES 1 Flexible 1 Kraftstofftank-Lüfterschlauch 1 Tubo respiradero del depósito de combus- reniflard réservoir d’essence 2 Klammer tible 2 Bride 3 Diode...
Página 162 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM Ï Fasten the wire harness, TPS  Fasten the neutral switch lead Ø Pass the wire harness on the lead (in the wire harness), to the frame with a plastic band outside of the neutral switch starter motor lead and negative ends outward.
Página 163 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC DIAGRAMA DE RUTA DE CABLES Ï Attacher le faisceau de câbles, le câble Ï Den Kabelbaum, die TPS-Leitung (im Ï Sujete el cableado, cable del TPS (en el TPS (dans le faisccou de câbles) le câble Kabelbaum) die Startermotorleitung cableado) cable del motor de arranque y...
Página 164 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM Å Pass the throttle cables, clutch Ï Fasten the grommet of the clutch 1 Hot starter cable 2 Clutch cable cable and hot starter cable through cable with the cable holder. Ì...
Página 165 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC DIAGRAMA DE RUTA DE CABLES 1 Câble de démarrage à chaud 1 Heißstarter-Seilzug 1 Cable de arranque en caliente 2 Câble d’embrayage 2 Kupplungsseilzug 2 Cable del embrague 3 Câble d’accélérateur (rentré) 3 Gasseilzug (Rückzug) 3 Cable del acelerador (retornar)
Página 166 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM Å Install the brake hose so that its 1 Master cylinder 2 Brake hose holder pipe portion directs as shown and 3 Brake hose lightly touches the projection on the caliper.
Página 167 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC DIAGRAMA DE RUTA DE CABLES 1 Maître-cylindre 1 Hauptzylinder 1 Cilindro principal 2 Support de flexible de frein 2 Bremsschlauchhalter 2 Soporte del tubo del freno 3 Tuyau de frein 3 Bremsschlauch 3 Tubo del freno Å...
Página 168 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM Å Position the starter motor lead, Ï Pass the coolant reservoir hose 1 Starter motor lead 2 Negative battery lead negative battery lead and wire on the outside of the coolant res- 3 Wire harness harness in the tank damper slit.
Página 169 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC DIAGRAMA DE RUTA DE CABLES 1 Câble de démarreur 1 Startermotorleitung 1 Cable del motor de arranque 2 Câble négatif de batterie 2 Minus-Batteriekabel 2 Cable negativo de la batería 3 Faisceau de câbles 3 Kabelbaum 3 Cableado...
Página 170 All manuals and user guides at all-guides.com SPEC CABLE ROUTING DIAGRAM Å Fasten the start switch lead to the Ï Pass the throttle cables and clutch 1 Throttle cable 2 Clamp handlebar with the plastic bands. cable between the handle crown ı...
Página 171 All manuals and user guides at all-guides.com CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC DIAGRAMA DE RUTA DE CABLES 1 Câble d’accélérateur 1 Gasseilzug 1 Cable del acelerador 2 Bride 2 Klammer 2 Abrazadera 3 Tuyau de frein 3 Bremsschlauch 3 Tubo del freno 4 Câble de démarrage à...
Página 172: Maintenance Intervals
If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every...
Página 173 All manuals and user guides at all-guides.com 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 ● ●...
Página 174 ● 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 HOT STARTER, CLUTCH LEVER ●...
Página 175: Controles Et Reglages Courants
Sa machine ont une grande influence sur les intervalles d’entretien et de lubrification. En cas de doute au sujet des intervalles d’entretien et de lubrification à adopter, consulter son concessionnaire Yamaha. Chaque Chaque Après...
Página 176 All manuals and user guides at all-guides.com INSP PROGRAMME D’ENTRETIEN Chaque Chaque Après Chaque ème ème Partie néces- Remarques rodage course 500 km 1.000 km saire ECROU DU ROTOR ● ● Resserrer POT D’ECHAPPEMENT ● ● Contrôler et resserrer ● Nettoyer * A la première des deux ●...
Página 177 Changer les roulements ● Graisser Graisse à base de lithium ACCELERATEUR, CABLES DE COM- MANDE ● ● Contrôler le cheminement et le branche- Yamaha lube pour câble ou ment Huile moteur SAE 10W-30 ● ● Graisser DEMARREUR A CHAUD, LEVIER D’EMBRAYAGE ●...
Página 178 Die hier empfohlenen Zeitabstände für Wartung und Schmierung sollten jedoch lediglich als Richt- werte für den Normalbetrieb angesehen werden. Je nach Wetterbedingungen, Belastung und Ein- satzgebiet können in Abweichung des regelmäßigen Wartungsplans kürzere Intervalle notwendig werden. Richten Sie etwaige Fragen zu den Wartungs- und Schmierintervallen bitte an Ihren Yamaha-Händler. Nach Jedes Jedes...
Página 179: Wartungsintervalle Und Schmierdienst
All manuals and user guides at all-guides.com INSP WARTUNGSINTERVALLE UND SCHMIERDIENST Nach Jedes Jedes Nach dritte fünfte Nach Bezeichnung jedem Bemerkungen Ein- oder alle oder alle Bedarf Rennen fahren 500 km 1.000 km ROTORMUTTER ● ● Nachziehen SCHALLDÄMPFER ● ● Prüfen und reinigen ●...
Página 180 All manuals and user guides at all-guides.com INSP WARTUNGSINTERVALLE UND SCHMIERDIENST Nach Jedes Jedes Nach dritte fünfte Nach Bezeichnung jedem Bemerkungen Ein- oder alle oder alle Bedarf Rennen fahren 500 km 1.000 km TELESKOPGABEL ● ● Prüfen und einstellen ● ●...
Página 181 Tenga en cuenta que factores como el tiempo, el terreno, la ubicación geográfica y el uso individualizado pue- den alterar los intervalos de mantenimiento y lubricación requeridos. Si tiene alguna duda acerca de los inter- valos que debe seguir en el mantenimiento y la lubricación del vehículo, consulte con su concesionario Yamaha. Cuando Des-...
Página 182: Intervalos De Mantenimiento
All manuals and user guides at all-guides.com INSP INTERVALOS DE MANTENIMIENTO Cuando Des- Cada En cada Cada tres Ítem pués del cinco o Observaciones carrera o 500 km necesa- rodaje 1.000 km TUERCA DEL ROTOR ● ● Ajustar nuevamente SILENCIADOR ●...
Página 183 Lubricar Grasa con base de litio ACELERADOR, CABLE DE CONTROL ● ● Comprobar la ruta de cables y las Lubricante del cable conexiones Yamaha o aceite de motor ● ● Lubricar SAE 10W-30 ARRANCADOR EN CALIENTE, PALANCA DEL EMBRAGUE ●...
Página 184: Pre-Operation Inspection And Maintenance
All manuals and user guides at all-guides.com INSP PRE-OPERATION INSPECTION AND MAINTENANCE EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine...
Página 185: Controle Et Entretien Avant Utilisation
All manuals and user guides at all-guides.com INSP CONTROLE ET ENTRETIEN AVANT UTILISATION CONTROLE ET ENTRETIEN AVANT UTILISATION Avant la conduite pour le rodage, l’entraînement ou une course, s’assurer que la machine est en bon état de marche. Avant d’utiliser cette machine, contrôler les points suivants. CONTROLE GENERAL ET ENTRETIEN Partie Routine...
Página 186: Wartungs- Und Einstellarbeiten Vor Fahrtbeginn
All manuals and user guides at all-guides.com WARTUNGS- UND EINSTELLARBEITEN VOR INSP FAHRTBEGINN WARTUNGS- UND EINSTELLARBEITEN VOR FAHRTBEGINN Der Betriebszustand der Maschine muß sowohl vor dem Einfahren als auch vor jeder Übungs- und Rennfahrt überprüft werden. Vor Fahrtbeginn neben einer gewissenhaften Sichtkontrolle folgende Punkte prüfen. ROUTINEKONTROLLE VOR FAHRTBEGINN Bezeichnung Ausführung...
Página 187: Inspección Y Mantenimiento Generales
All manuals and user guides at all-guides.com INSP INSPECCIÓN Y MANTENIMIENTO PREVIOS A LA CONDUCCIÓN INSPECCIÓN Y MANTENIMIENTO PREVIOS A LA CONDUCCIÓN Antes de conducir el vehículo para llevar a cabo el rodaje, practicar o participar en una carrera, asegúrese de que el vehículo esté...
Página 188 All manuals and user guides at all-guides.com ENGINE/COOLANT LEVEL INSPECTION/ INSP COOLANT REPLACEMENT 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.
Página 189: Moteur
All manuals and user guides at all-guides.com MOTEUR/CONTROLE DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT/ CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP MOTOR/KÜHLFLÜSSIGKEITSTAND KONTROLLIEREN/KÜHLFLÜSSIGKEIT WECHSELN MOTOR/INSPECCIÓN DEL NIVEL DE REFRIGERANTE/ SUSTITUCIÓN DEL REFRIGERANTE MOTEUR MOTOR MOTOR KÜHLFLÜSSIGKEITSTAND CONTROLE DU NIVEAU DU INSPECCIÓN DEL NIVEL DE KONTROLLIEREN LIQUIDE DE REFROIDISSEMENT REFRIGERANTE...
Página 190 All manuals and user guides at all-guides.com INSP COOLANT REPLACEMENT CAUTION: Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: Seat Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
Página 191 All manuals and user guides at all-guides.com CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP KÜHLFLÜSSIGKEIT WECHSELN SUSTITUCIÓN DEL REFRIGERANTE ACHTUNG: ATTENTION: ATENCION: Prendre garde à ne pas verser de Darauf achten, daß keine Kühlflüs- Evite que el refrigerante se derrame liquide de refroidissement sur les sur- sigkeit auf lackierte Flächen ge- sobre las superficies pintadas.
Página 192 All manuals and user guides at all-guides.com INSP COOLANT REPLACEMENT 9. Fill: Radiator Engine To specified level. Recommended coolant: High quality ethylene glycol anti-freeze containing anti-corrosion for aluminum engine Coolant 1 and water (soft water) 2 mixing ratio: 50%/50% Coolant capacity: 1.25 L (1.10 Imp qt, 1.32 US qt) CAUTION: Do not mix more than one type of ethyl-...
Página 193 All manuals and user guides at all-guides.com CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP KÜHLFLÜSSIGKEIT WECHSELN SUSTITUCIÓN DEL REFRIGERANTE 9. Befüllen: Remplir: Rellenar: Kühler Radiateur Radiador Moteur Motor Motor Au niveau spécifié. (bis zum vorgeschriebenen Hasta el nivel especificado. Stand) Liquide refroidisse- Refrigerante recomen-...
Página 194: Yu-24460-01/90890-01325
All manuals and user guides at all-guides.com RADIATOR CAP INSPECTION/ INSP RADIATOR CAP OPENING PRESSURE INSPECTION 12. Install: Coolant reservoir cap 13. Start the engine and let it warm up for several minutes. 14. Turn off the engine and inspect the cool- ant level.
Página 195: Yu-33984/90890-01352
All manuals and user guides at all-guides.com CONTROLE DU BOUCHON DU RADIATEUR/CONTROLE DE LA PRESSION D’OUVERTURE DU BOUCHON DU RADIATEUR KÜHLERDECKEL KONTROLLIEREN/KÜHLERVERSCHLUSSDECKEL- INSP ÖFFNUNGSDRUCK KONTROLLIEREN/ INSPECCIÓN DE LA TAPA DEL RADIADOR/INSPECCIÓN DE LA PRESIÓN DE APERTURA DE LA TAPA DEL RADIADOR 12.
Página 196: Yu-24460-01/90890-01325
All manuals and user guides at all-guides.com INSP COOLING SYSTEM INSPECTION 3. Inspect: Pressure Impossible to maintain the specified pressure for 10 seconds → Replace. EC357002 COOLING SYSTEM INSPECTION 1. Inspect: Coolant level 2. Attach: Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Adapter:...
Página 197: Inspección Del Sistema De Refrigeración
All manuals and user guides at all-guides.com CONTROLE DU SYSTEME DE REFROIDISSEMENT INSP KÜHLSYSTEM KONTROLLIEREN INSPECCIÓN DEL SISTEMA DE REFRIGERACIÓN 3. Kontrollieren: Vérifier: Inspeccionar: Druck Pression Presión Impossible de maintenir la Druckverlust innerhalb 10 Imposible mantener la presión Sekunden → Erneuern. pression spécifiée pendant 10 especificada durante 10 segun- secondes →...
Página 198: Clutch Adjustment
All manuals and user guides at all-guides.com CLUTCH ADJUSTMENT/ INSP THROTTLE CABLE ADJUSTMENT EC359020 CLUTCH ADJUSTMENT 1. Check: Clutch lever free play a Out of specification → Adjust. Clutch lever free play a: 8 ~ 13 mm (0.31 ~ 0.51 in) 2.
Página 199 All manuals and user guides at all-guides.com INSP REGLAGE DE L’EMBRAYAGE/REGLAGE DES CABLES D’ACCELERATION KUPPLUNG EINSTELLEN/GASZUGSPIEL EINSTELLEN AJUSTE DEL EMBRAGUE/AJUSTE DEL CABLE DEL ACELERADOR KUPPLUNG EINSTELLEN REGLAGE DE L’EMBRAYAGE AJUSTE DEL EMBRAGUE 1. Kontrollieren: Contrôler: Comprobar: Jeu du levier d’embrayage a Kupplungszugspiel a Juego libre de la palanca del Hors spécification →...
Página 200 All manuals and user guides at all-guides.com THROTTLE LUBRICATION/ INSP HOT STARTER LEVER ADJUSTMENT NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. WARNING After adjusting the throttle cable free play, start the engine and turn the han- dlebar to right and left and make sure that the engine idling does not run faster.
Página 201 All manuals and user guides at all-guides.com GRAISSAGE DE L’ACCELERATEUR/REGLAGE DU LEVIER DE DEMARREUR A CHAUD INSP GASZUG SCHMIEREN/WARMSTART-HEBEL-EINSTELLUNG LUBRICACIÓN DEL ACELERADOR/ AJUSTE DE LA PALANCA DE ARRANQUE EN CALIENTE HINWEIS: N.B.: NOTA: Vor dem Einstellen des Gaszug- Avant de régler le jeu des câbles de Antes de ajustar el juego libre del spiels sollte die Leerlaufdrehzahl d’accélération, il faut régler la vitesse...
Página 202 All manuals and user guides at all-guides.com INSP AIR FILTER CLEANING AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. CAUTION: Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage.
Página 203: Nettoyage Du Filtre A Air
All manuals and user guides at all-guides.com NETTOYAGE DU FILTRE A AIR INSP LUFTFILTER REINIGEN LIMPIEZA DEL FILTRO DE AIRE LUFTFILTER REINIGEN NETTOYAGE DU FILTRE A AIR LIMPIEZA DEL FILTRO DE AIRE HINWEIS: N.B.: NOTA: Un entretien convenable du filtre à air Frühzeitige sachgemäße Un mantenimiento del filtro apropiado...
Página 204: Air Filter Cleaning
All manuals and user guides at all-guides.com INSP AIR FILTER CLEANING CAUTION: Do not twist the element when squeezing the element. Leaving too much of solvent in the ele- ment may result in poor starting. 5. Inspect: Air filter element Damage →...
Página 205 All manuals and user guides at all-guides.com NETTOYAGE DU FILTRE A AIR INSP LUFTFILTER REINIGEN LIMPIEZA DEL FILTRO DE AIRE ACHTUNG: ATTENTION: ATENCION: Ne pas tordre l’élément en l’esso- Den Filterschaumstoff vorsich- No retuerza el elemento al presionar. rant. tig ausdrükken, nicht wringen. Si quedan demasiados restos de Un excès de dissolvant sur l’élément Überschüssige...
Página 206 All manuals and user guides at all-guides.com INSP ENGINE OIL LEVEL INSPECTION ENGINE OIL LEVEL INSPECTION 1. Stand the motorcycle on a level surface. NOTE: When checking the oil level make sure that the motorcycle is upright. Place the motorcycle on a suitable stand. WARNING Never remove the oil tank cap just after high speed operation.
Página 207 All manuals and user guides at all-guides.com CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN INSPECCIÓN DEL NIVEL DE ACEITE DE MOTOR MOTORÖLSTAND KONTROLLIE- CONTROLE DU NIVEAU D’HUILE INSPECCIÓN DEL NIVEL DE MOTEUR ACEITE DE MOTOR Placer la motocyclette sur une 1.
Página 208 All manuals and user guides at all-guides.com INSP ENGINE OIL LEVEL INSPECTION (For USA and CDN) Recommended oil: At 5 ˚C (40 ˚F) or higher Å Yamalube 4 (20W-40) or SAE 20W-40 type SG motor oil (Non-Friction modified) At 15 ˚C (60 ˚F) or lower ı Yamalube 4 (10W-30) or SAE 10W-30 type SG motor oil (Non-Friction modified)
Página 209 All manuals and user guides at all-guides.com CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN INSPECCIÓN DEL NIVEL DE ACEITE DE MOTOR (Nur USA und CDN) (USA et CDN) (Para USA y CDN) Empfohlene Ölsorte Huile recommandée: Aceite recomendado: Min. 5 ˚C (40 ˚F) Å: (Viskosität): 5 ˚C (40 ˚F) o superior Å...
Página 210: Engine Oil Replacement
All manuals and user guides at all-guides.com INSP ENGINE OIL REPLACEMENT 6. Idle the engine more than 10 seconds while keeping the motorcycle upright. Then stop the engine and add the oil to the maximum level. 7. Install: Oil tank cap ENGINE OIL REPLACEMENT 1.
Página 211: Motoröl Wechseln
All manuals and user guides at all-guides.com CHANGEMENT DE L’HUILE DE MOTEUR INSP MOTORÖL WECHSELN SUSTITUCIÓN DEL ACEITE DE MOTOR 6. Den Motor mindestens 10 Se- Faire tourner le moteur au ralenti Deje el motor en ralentí durante kunden lang in gerader Stel- pendant environ 10 secondes tout más de 10 segundos mientras man- lung im Leerlauf laufen betrei-...
Página 212 All manuals and user guides at all-guides.com INSP ENGINE OIL REPLACEMENT 6. 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 cover 1 and oil filter element 2.
Página 213 All manuals and user guides at all-guides.com CHANGEMENT DE L’HUILE DE MOTEUR INSP MOTORÖL WECHSELN SUSTITUCIÓN DEL ACEITE DE MOTOR 6. Soll auch der Ölfilter gewech- S’il est nécessaire de remplacer le Si también es necesario cambiar selt werden, müssen zusätz- filtre à...
Página 214 All manuals and user guides at all-guides.com INSP PILOT SCREW ADJUSTMENT 10. Install: Oil filler plug 11. Inspect: Engine (for oil leaks) Oil level Refer to “ENGINE OIL LEVEL INSPEC- TION”. 12. Check: Oil pressure Checking steps: Slightly loosen the oil gallery bolt 1. Start the engine and keep it idling until oil starts to seep from the oil gallery bolt.
Página 215: Reglage De La Vis De Richesse Leerlaufgemisch Einstellen Ajuste Del Tornillo Piloto
All manuals and user guides at all-guides.com REGLAGE DE LA VIS DE RICHESSE INSP LEERLAUFGEMISCH EINSTELLEN AJUSTE DEL TORNILLO PILOTO 10. Montieren: 10. Monter: 10. Instalar: Motoröl-Einfüllschraubver- Bouchon de l’orifice de rem- Tapón de llenado de aceite plissage d’huile schluß 11.
Página 216: Idle Speed Adjustment
All manuals and user guides at all-guides.com IDLE SPEED ADJUSTMENT/ INSP VALVE CLEARANCE ADJUSTMENT EC35M021 IDLE SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it 2. Adjust: Idle speed Adjustment steps: Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section.
Página 217 All manuals and user guides at all-guides.com INSP REGLAGE DU REGIME DE RALENTI/REGLAGE DU JEU DE SOUPAPES LEERLAUFDREHZAHL EINSTELEN/VENTILSPIEL EINSTELLEN AJUSTE DE LA VELOCIDAD DE RALENTÍ/AJUSTE DE LA HOLGURA DE LA VÁLVULA LEERLAUFDREHZAHL EINSTE- REGLAGE DU REGIME DE AJUSTE DE LA VELOCIDAD DE RALENTI RALENTÍ...
Página 218: Valve Clearance Adjustment
All manuals and user guides at all-guides.com INSP VALVE CLEARANCE ADJUSTMENT 3. Remove: Timing plug 1 Straight plug 2 O-ring 4. Check: Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) Exhaust valve: 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in)
Página 219 All manuals and user guides at all-guides.com REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL EINSTELLEN AJUSTE DE LA HOLGURA DE LA VÁLVULA 3. Demontieren: Déposer: Extraer: Bouchon de distribution 1 Schwungrad-Abdeckschrau- Tapón de distribución 1 Bouchon droit 2 be 1 Tapón plano 2 Joint torique Rotorzapfen-Abdeckschrau-...
Página 220 All manuals and user guides at all-guides.com INSP VALVE CLEARANCE ADJUSTMENT 5. Adjust: Valve clearance Adjustment steps: Loosen the timing chain tensioner cap bolt. Remove the timing chain tensioner and camshaft caps. NOTE: Remove the camshaft cap bolts in a criss- cross pattern from the outside working inwards.
Página 221 All manuals and user guides at all-guides.com REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL EINSTELLEN AJUSTE DE LA HOLGURA DE LA VÁLVULA 5. Einstellen: Régler: Ajustar: Ventilspiel Jeu de soupapes Holgura de la válvula Etapes du réglage: Arbeitsschritte: Pasos de ajuste: Steuerkettenspanner-Abdeck- Desserrer le boulon capuchon du Afloje el perno de la tapa del tensa-...
Página 222 All manuals and user guides at all-guides.com INSP VALVE CLEARANCE ADJUSTMENT Round off the last digit of the installed pad number to the nearest increment. Last digit of pad Rounded value number 0, 1 or 2 4, 5 or 6 8 or 9 EXAMPLE: Installed pad number = 148...
Página 223 All manuals and user guides at all-guides.com REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL EINSTELLEN AJUSTE DE LA HOLGURA DE LA VÁLVULA Arrondir le dernier chiffre de la cale Hundertstel gemäß Tabelle run- Redondee el último dígito del installée à l’épaisseur de cale dispo- den.
Página 224 All manuals and user guides at all-guides.com INSP VALVE CLEARANCE ADJUSTMENT Install the timing chain tensioner. Refer to “CAMSHAFTS” section in the CHAPTER 4. NOTE: Turn the crankshaft counterclockwise sev- eral turns so that the installed parts settle into the right position. Recheck the valve clearance.
Página 225 All manuals and user guides at all-guides.com REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL EINSTELLEN AJUSTE DE LA HOLGURA DE LA VÁLVULA Steuerkettenspanner montieren. Monter le tendeur de la chaîne de Instale el tensador de la cadena de Siehe unter “NOCKENWELLE” distribution.
Página 226 All manuals and user guides at all-guides.com INSP VALVE CLEARANCE ADJUSTMENT INTAKE INSTALLED PAD NUMBER MEASURED CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09...
Página 227 All manuals and user guides at all-guides.com INSP REGLAGE DU JEU DE SOUPAPES ADMISSION NUMERO DE CALE INSTALLEE JEU MESURE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00 à...
Página 228 All manuals and user guides at all-guides.com INSP VENTILSPIEL EINSTELLEN EINLASS GEMESSE- NUMMER DES AUSGEBAUTEN VENTILPLÄTTCHENS NES SPIEL 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00–0,04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0,05–0,09...
Página 229: Ajuste De La Holgura De La Válvula
All manuals and user guides at all-guides.com INSP AJUSTE DE LA HOLGURA DE LA VÁLVULA ADMISIÓN JUEGO NÚMERO DE SUPLEMENTO INSTALADO MEDIDO 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...
Página 230 All manuals and user guides at all-guides.com INSP SPARK ARRESTER CLEANING (For USA) SPARK ARRESTER CLEANING (For USA) WARNING Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. Do not start the engine when cleaning the exhaust system.
Página 231 All manuals and user guides at all-guides.com NETTOYAGE DU PARE-ETINCELLES (pour les USA) INSP FUNKENFÄNGER REINIGEN (Nur USA) LIMPIEZA DEL AMORTIGUADOR DE CHISPAS (Para USA) FUNKENFÄNGER REINIGEN (Nur NETTOYAGE DU PARE-ETINCEL- LIMPIEZA DEL AMORTIGUA- USA) LES (pour les USA) DOR DE CHISPAS (Para USA) AVERTISSEMENT WARNUNG ADVERTENCIA...
Página 232 All manuals and user guides at all-guides.com INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING WARNING Bleed the brake system if: The system has been disassembled. A brake hose has been loosened or removed. The brake fluid is very low. The brake operation is faulty.
Página 233: Partie Cycle
All manuals and user guides at all-guides.com PARTIE CYCLE/PURGE DE L’AIR DU SYSTEME DE FREINAGE INSP FAHRWERK/HYDRAULISCHE BREMSANLAGE ENTLÜFTEN CHASIS/PURGA DEL AIRE DEL SISTEMA DE FRENOS PARTIE CYCLE FAHRWERK CHASIS HYDRAULISCHE BREMSANLAGE PURGE DE L’AIR DU SYSTEME PURGA DEL AIRE DEL SISTEMA ENTLÜFTEN DE FREINAGE DE FRENOS...
Página 234 All manuals and user guides at all-guides.com INSP FRONT BRAKE ADJUSTMENT NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disap- peared.
Página 235: Reglage De Frein Avant
All manuals and user guides at all-guides.com REGLAGE DE FREIN AVANT INSP VORDERRADBREMSE EINSTELLEN AJUSTE DEL FRENO DELANTERO N.B.: HINWEIS: NOTA: Si la purge est difficile, il peut être Kann die Anlage nicht zufrieden- Si resulta difícil efectuar la purga, nécessaire de laisser le système du stellend entlüftet werden, sollte die puede ser necesario dejar que se esta-...
Página 236 All manuals and user guides at all-guides.com REAR BRAKE ADJUSTMENT/ INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMENT 1. Check: Brake pedal height a Out of specification → Adjust. Brake pedal height a: 5 mm (0.20 in) 2.
Página 237 All manuals and user guides at all-guides.com REGLAGE DU FREIN ARRIERE/ CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN AVANT HINTERRADBREMSE EINSTELLEN/ INSP VORDERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN AJUSTE DEL FRENO TRASERO/ INSPECCIÓN Y SUSTITUCIÓN DE LAS PASTILLAS DEL FRENO DELANTERO HINTERRADBREMSE EINSTEL- REGLAGE DU FREIN ARRIERE AJUSTE DEL FRENO TRASERO Contôler:...
Página 238 All manuals and user guides at all-guides.com INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT Loosen the pad pin 2. Remove the brake hose holder 3 and cal- iper 4 from the front fork. Remove the pad pin and brake pads 5. Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end.
Página 239 All manuals and user guides at all-guides.com INSP CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN AVANT VORDERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN INSPECCIÓN Y SUSTITUCIÓN DE LAS PASTILLAS DEL FRENO DELANTERO Desserrer la goupille de plaquette Haltestift 2 demontieren. Afloje el bulón de la pastilla 2. Bremsschlauchhalterung Extraiga el soporte del tubo de fre- Déposer le support du tuyau de...
Página 240 All manuals and user guides at all-guides.com INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT Install the pad pin plug B. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION”...
Página 241 All manuals and user guides at all-guides.com INSP CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN ARRIERE HINTERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN INSPECCIÓN Y SUSTITUCIÓN DE LA PASTILLA DEL FRENO TRASERO Installer le bouchon de goupille de Haltestift B montieren. Instale el tapón del bulón de la pas- plaquette B.
Página 242 All manuals and user guides at all-guides.com INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT Remove the pad pin 6 and brake pads 7. Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. Loosen the bleed screw and push the cali- per piston in.
Página 243 All manuals and user guides at all-guides.com INSP CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN ARRIERE HINTERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN INSPECCIÓN Y SUSTITUCIÓN DE LA PASTILLA DEL FRENO TRASERO Déposer la goupille de plaquette 6 Haltestift 6 und Bremsbeläge Extraiga el bulón de la pastilla 6 y et les plaquettes de frein 7.
Página 244 All manuals and user guides at all-guides.com REAR BRAKE PAD INSULATOR INSPECTION/ INSP BRAKE FLUID LEVEL INSPECTION 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: Brake pedal operation A softy or spongy feeling → Bleed brake system.
Página 245 All manuals and user guides at all-guides.com VERIFICATION DE L’ISOLANT DE LA PLAQUETTE DE FREIN ARRIERE/ CONTROLE DU NIVEAU DU LIQUIDE DE FREIN INSPEKTION DER ISOLIERUNG DES HINTERRADBREMSBELAGS/ INSP BREMSFLÜSSIGKEITSSTAND KONTROLLIEREN INSPECCIÓN DEL AISLADOR DE LA PASTILLA DEL FRENO TRASERO/ INSPECCIÓN DEL NIVEL DE LÍQUIDO DE FRENOS 3.
Página 246 All manuals and user guides at all-guides.com INSP SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION EC368000 SPROCKETS INSPECTION 1. Inspect: Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set. DRIVE CHAIN INSPECTION 1. Remove: Drive chain 1 NOTE: Remove the drive chain using a chain cutter...
Página 247 All manuals and user guides at all-guides.com INSP CONTROLE DES PIGNONS/CONTROLE DE LA CHAINE DE TRANSMISSION KETTENRÄDER KONTROLLIEREN/ANTRIEBSKETTE KONTROLLIEREN INSPECCIÓN DE LOS PIÑONES/INSPECCIÓN DE LA CADENA DE TRANSMISIÓN KETTENRÄDER KONTROLLIE- CONTROLE DES PIGNONS INSPECCIÓN DE LOS PIÑONES Contrôler: Inspeccionar: Dent de pignon a Diente del piñón a 1.
Página 248: Drive Chain Inspection
All manuals and user guides at all-guides.com INSP DRIVE CHAIN INSPECTION 5. Check: Drive chain stiffness a Clean and oil the chain and hold as illustrated. Stiff → Replace the drive chain. 6. Install: Joint 1 O-ring 2 Drive chain 3 NOTE: When installing the drive chain, apply the lith- ium soap base grease on the joint and O-rings.
Página 249 All manuals and user guides at all-guides.com CONTROLE DE LA CHAINE DE TRANSMISSION INSP ANTRIEBSKETTE KONTROLLIEREN INSPECCIÓN DE LA CADENA DE TRANSMISIÓN 5. Kontrollieren: Contrôler: Comprobar: Antriebskette (Beweglich- Raideur de la chaîne de trans- Rigidez de la cadena de trans- mission a keit) a misióne a...
Página 250 All manuals and user guides at all-guides.com INSP DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Check: Drive chain slack a Above the seal guard installation bolt. Out of specification →...
Página 251 All manuals and user guides at all-guides.com REGLAGE DE LA FLECHE DE CHAINE DE TRANSMISSION INSP ANTRIEBSKETTEN-DURCHHANG EINSTELLEN AJUSTE DE LA TENSIÓN DE LA CADENA DE TRANSMISIÓN ANTRIEBSKETTEN-DURCHHANG REGLAGE DE LA FLECHE DE AJUSTE DE LA TENSIÓN DE LA EINSTELLEN CHAINE DE TRANSMISSION CADENA DE TRANSMISIÓN Surélever la roue arrière en pla-...
Página 252 All manuals and user guides at all-guides.com INSP DRIVE CHAIN STOPPER INSPECTION/FRONT FORK INSPECTION/ FRONT FORK OIL SEAL AND DUST SEAL CLEANING Tighten the axle nut while pushing down the drive chain. Axle nut: 125 Nm (12.5 m • kg, 90 ft • lb) Tighten the locknuts.
Página 253 All manuals and user guides at all-guides.com INSPECTION DE LA BUTEE DE CHAINE DE TRANSMISSION/CONTROLE DE LA FOURCHE AVANT/ NETTOYAGE DE BAGUE D’ETANCHEITE ET DE JOINT ANTIPOUSSIERE DE FOURCHE AVANT KONTROLLE DES ANTRIEBSKETTENANSCHLAGS/TELESKOPGABEL INSP KONTROLLIEREN/GABELDICHTRING UND STAUBMANSCHETTE REINIGEN INSPECCIÓN DEL TOPE DE LA CADENA DE TRANSMISIÓN/INSPECCIÓN DE LA HORQUILLA DELANTERA/LIMPIEZA DE GUARDAPOLVOS Y SELLOS DE ACEITE DE LA HORQUILLA DELANTERA Serrer l’écrou de l’axe tout en Achsmutter festziehen.
Página 254 All manuals and user guides at all-guides.com INSP FRONT FORK INTERNAL PRESSURE RELIEVING/ FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT FRONT FORK INTERNAL PRESSURE RELIEVING NOTE: If the front fork initial movement feels stiff dur- ing a run, relieve the front fork internal pres- sure.
Página 255 All manuals and user guides at all-guides.com PURGE DE L’AIR DE LA FOURCHE AVANT/REGLAGE DE LA FORCE D’AMORTISSEMENT DE REBOND DE LA FOURCHE AVANT TELESKOPKABEL-INNENDRUCKVERRINGERUNG/TELESKOPGABEL- INSP ZUGSTUFENDÄMPFUNG EINSTELLEN ALIVIO DE LA PRESIÓN INTERNA DE LA HORQUILLA DELANTERA/AJUSTE DE LA TENSIÓN DE RETORNO DEL AMORTIGUADOR DE LA HORQUILLA DELANTERA TELESKOPKABEL-INNENDRUCK- PURGE DE L’AIR DE LA FOUR- ALIVIO DE LA PRESIÓN...
Página 256 All manuals and user guides at all-guides.com FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. Standard position: 6 clicks out * 8 clicks out * For EUROPE, AUS, NZ and ZA CAUTION:...
Página 257 All manuals and user guides at all-guides.com REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION DE LA FOURCHE AVANT INSP TELESKOPGABEL-DRUCKSTUFEN-DÄMPFUNG EINSTELLEN AJUSTE DE LA TENSIÓN DEL AMORTIGUADOR DE COMPRESIÓN DE LA HORQUILLA DELANTERA NORMALEINSTELLUNG: POSITION STANDARD: POSICIÓN ESTÁNDAR: Zum Erreichen der Normaleinstel- C’est la position qui se trouve en Esta es la posición a la que vuelve por arrière du nombre spécifié...
Página 258 All manuals and user guides at all-guides.com INSP REAR SHOCK ABSORBER INSPECTION STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. Standard position: 15 clicks out CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment.
Página 259 All manuals and user guides at all-guides.com CONTROLE DE L’AMORTISSEUR ARRIERE INSP FEDERBEIN KONTROLLIEREN INSPECCIÓN DEL AMORTIGUADOR TRASERO NORMALEINSTELLUNG: POSITION STANDARD: POSICIÓN ESTÁNDAR: Zum Erreichen der Normaleinstel- C’est la position qui se trouve en Esta es la posición a la que vuelve por arrière du nombre spécifié...
Página 260 All manuals and user guides at all-guides.com REAR SHOCK ABSORBER SPRING PRELOAD INSP ADJUSTMENT REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: Rear frame 3. Loosen: Locknut 1 4.
Página 261 All manuals and user guides at all-guides.com INSP REGLAGE DE LA PRECONTRAINTE DE RESSORT DE L’AMORTISSEUR ARRIERE FEDERBEIN-FEDERVORSPANNUNG EINSTELLEN AJUSTE DE LA PRECARGA DEL MUELLE DEL AMORTIGUADOR TRASERO FEDERBEIN-FEDERVORSPAN- REGLAGE DE LA PRECON- AJUSTE DE LA PRECARGA DEL NUNG EINSTELLEN TRAINTE DE RESSORT DE MUELLE DEL AMORTIGUADOR L’AMORTISSEUR ARRIERE...
Página 262 All manuals and user guides at all-guides.com REAR SHOCK ABSORBER REBOUND DAMPING FORCE INSP 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.
Página 263 All manuals and user guides at all-guides.com REGLAGE DE LA FORCE D’AMORTISSEMENT DE REBOND DE L’AMORTISSEUR INSP ARRIERE FEDERBEIN-ZUGSTUFENDÄMPFUNG EINSTELLEN AJUSTE DE LA TENSIÓN DE RETORNO DEL AMORTIGUADOR TRASERO FEDERBEIN-ZUGSTUFENDÄMP- REGLAGE DE LA FORCE AJUSTE DE LA TENSIÓN DE FUNG EINSTELLEN D’AMORTISSEMENT DE REBOND RETORNO DEL AMORTIGUA- DE L’AMORTISSEUR ARRIERE...
Página 264 All manuals and user guides at all-guides.com REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: Low compression damping force By turning the adjuster 1. Stiffer a → Increase the low compres- sion damping force.
Página 265 All manuals and user guides at all-guides.com REGLAGE DE LA FORCE D’AMORTISSEMENT A BASSE COMPRESSION DE L’AMORTISSEUR ARRIERE INSP EINSTELLUNG DER FEDERBEIN-DRUCKSTUFENDÄMPFUNG AJUSTE DE LA TENSIÓN DE RETORNO DE COMPRESIÓN BAJA DEL AMORTIGUADOR TRASERO EINSTELLUNG DER FEDERBEIN- REGLAGE DE LA FORCE AJUSTE DE LA TENSIÓN DE DRUCKSTUFENDÄMPFUNG D’AMORTISSEMENT A BASSE...
Página 266 All manuals and user guides at all-guides.com REAR SHOCK ABSORBER HIGH COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: High compression damping force By turning the adjuster 1. Stiffer a → Increase the high compres- sion damping force.
Página 267 All manuals and user guides at all-guides.com REGLAGE DE LA FORCE D’AMORTISSEMENT A HAUTE COMPRESSION DE L’AMORTISSEUR ARRIERE INSP EINSTELLUNG DER FEDERBEIN-DRUCKSTUFENDÄMPFUNG AJUSTE DE LA TENSIÓN DE RETORNO DE COMPRESIÓN ALTA DEL AMORTIGUADOR TRASERO EINSTELLUNG DER FEDERBEIN- REGLAGE DE LA FORCE AJUSTE DE LA TENSIÓN DE DRUCKSTUFENDÄMPFUNG D’AMORTISSEMENT A HAUTE...
Página 268: Tire Pressure Check
All manuals and user guides at all-guides.com TIRE PRESSURE CHECK/SPOKES INSPECTION AND INSP TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm , 15 psi) NOTE: Check the tire while it is cold. Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
Página 269 All manuals and user guides at all-guides.com CONTROLE DE PRESSION DES PNEUS/CONTROLE ET SERRAGE DES RAYONS/ CONTROLE DE LA ROUE REIFENLUFTDRUCK KONTROLLIEREN/SPEICHEN KONTROLLIEREN UND INSP FESTZIEHEN/RÄDER KONTROLLIEREN COMPROBACIÓN DE LA PRESIÓN DE LOS NEUMÁTICOS/INSPECCIÓN Y AJUSTE DE LOS RADIOS/INSPECCIÓN DE RUEDAS REIFENLUFTDRUCK KONTROL- CONTROLE DE PRESSION DES...
Página 270: Yu-33975/90890-01403
All manuals and user guides at all-guides.com INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: Bearing free play Exist play → Replace. STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine. 2.
Página 271: Clé Pour Écrou Annulaire
All manuals and user guides at all-guides.com CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPF KONTROLLIEREN UND EINSTELLEN INSPECCIÓN Y AJUSTE DEL CABEZAL DE DIRECCIÓN 2. Kontrollieren: Vérifier: Inspeccionar: Lagerspiel Jeu de roulement Juego libre del cojinete Il y a du jeu → Changer. Spiel →...
Página 272: Yu-33975/90890-01403
All manuals and user guides at all-guides.com INSP STEERING HEAD INSPECTION AND ADJUSTMENT Tighten the ring nut 3 using ring nut wrench 4. NOTE: Set the torque wrench to the ring nut wrench so that they form a right angle. Ring nut wrench: YU-33975/90890-01403 Ring nut (initial tightening):...
Página 273 All manuals and user guides at all-guides.com CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPF KONTROLLIEREN UND EINSTELLEN INSPECCIÓN Y AJUSTE DEL CABEZAL DE DIRECCIÓN Serrer l’écrou annulaire en utilisant Ringmutter mit dem Haken- Apriete la tuerca anular con la llave schlüssel festziehen.
Página 274 All manuals and user guides at all-guides.com INSP LUBRICATION Å Use Yamaha cable lube or equivalent on these LUBRICATION areas. To ensure smooth operation of all compo- ı Use SAE 10W-30 motor oil or suitable chain nents, lubricate your machine during setup, lubricants.
Página 275: Lubricación
0 Extrémité du câble de démarreur à chaud 0 Heißstarterseilzug-Ende 0 Extremo del cable de arranque en caliente Å Mettre du lubrifiant Yamaha pour câbles, Å Yamaha Seilzug-Schmiermittel oder Å Utilice lubricante para cables Yamaha o ou équivalent sur ces parties.
Página 276: Spark Plug Inspection
All manuals and user guides at all-guides.com INSP ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: Spark plug 2. Inspect: Electrode 1 Wear/damage → Replace. Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color →...
Página 277: Partie Electrique
All manuals and user guides at all-guides.com PARTIE ELECTRIQUE/CONTROLE DE LA BOUGIE INSP ELEKTRISCHE ANLAGE/ZÜNDKERZE KONTROLLIEREN SISTEMA ELÉCTRICO/INSPECCIÓN DE LA BUJÍA PARTIE ELECTRIQUE ELEKTRISCHE ANLAGE SISTEMA ELÉCTRICO ZÜNDKERZE KONTROLLIEREN CONTROLE DE LA BOUGIE INSPECCIÓN DE LA BUJÍA 1. Demontieren: Déposer: Extraer: Zündkerze Bougie...
Página 278: Ym-33277-A/90890-03141
All manuals and user guides at all-guides.com INSP IGNITION TIMING CHECK IGNITION TIMING CHECK 1. Remove: Timing plug 1 2. Attach: Timing light Inductive tachometer To the ignition coil lead (orange lead Timing light: YM-33277-A/90890-03141 3. Adjust: Engine idling speed Refer to “IDLE SPEED ADJUST- MENT”.
Página 279: Lampe Stroboscopique
All manuals and user guides at all-guides.com CONTROLE DE L’AVANCE A L’ALLUMAGE INSP ZÜNDZEITPUNKT KONTROLLIEREN COMPROBACIÓN DE LA DISTRIBUCIÓN DE ENCENDIDO ZÜNDZEITPUNKT KONTROLLIE- CONTROLE DE L’AVANCE A COMPROBACIÓN DE LA DISTRI- L’ALLUMAGE BUCIÓN DE ENCENDIDO Déposer: 1. Demontieren: Extraer: Bouchon de distribution 1 Schwungrad-Abdeckschrau- Tapón de distribución 1 be 1...
Página 280 All manuals and user guides at all-guides.com INSP BATTERY INSPECTION AND CHARGING BATTERY INSPECTION AND CHARGING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near batteries.
Página 281 All manuals and user guides at all-guides.com CONTROLE ET RECHARGE DE LA BATTERIE INSP BATTERIE KONTROLLIEREN UND LADEN INSPECCIÓN Y CARGA DE LA BATERÍA BATTERIE KONTROLLIEREN UND CONTROLE ET RECHARGE DE INSPECCIÓN Y CARGA DE LA LADEN LA BATTERIE BATERÍA AVERTISSEMENT WARNUNG ADVERTENCIA...
Página 282 All manuals and user guides at all-guides.com INSP BATTERY INSPECTION AND CHARGING NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Página 283 All manuals and user guides at all-guides.com CONTROLE ET RECHARGE DE LA BATTERIE INSP BATTERIE KONTROLLIEREN UND LADEN INSPECCIÓN Y CARGA DE LA BATERÍA HINWEIS: N.B.: NOTA: Comme une batterie MF est scellée, il est Da die wartungsfreie Batterie dicht Puesto que las baterías sin manteni- impossible de vérifier son état de charge verschlossen ist, kann deren Lade-...
Página 284 All manuals and user guides at all-guides.com INSP BATTERY INSPECTION AND CHARGING Å Check the charge of the battery, as shown in the charts and the following example. Example Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge of the battery = 20 ~ 30% Å...
Página 285 All manuals and user guides at all-guides.com CONTROLE ET RECHARGE DE LA BATTERIE INSP BATTERIE KONTROLLIEREN UND LADEN INSPECCIÓN Y CARGA DE LA BATERÍA Contrôler la charge de la batterie, Den Ladezustand der Batterie Compruebe la carga de la batería conformément aux diagrammes et anhand der nebenstehenden como se muestra en las tablas y en...
Página 286 All manuals and user guides at all-guides.com INSP BATTERY INSPECTION AND CHARGING Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. Make sure the battery charger lead clips are in full contact with the battery termi- nal and that they are not shorted.
Página 287 All manuals and user guides at all-guides.com CONTROLE ET RECHARGE DE LA BATTERIE INSP BATTERIE KONTROLLIEREN UND LADEN INSPECCIÓN Y CARGA DE LA BATERÍA Ebenso die Anschlußklemmen Ne pas oublier de couper l’alimenta- Antes de quitar de los terminales de des Ladegeräts erst von den tion du chargeur avant de retirer les la batería las pinzas de los cables del...
Página 288 All manuals and user guides at all-guides.com INSP BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger 3 - 54...
Página 289 All manuals and user guides at all-guides.com INSP BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger 3 - 55...
Página 290 All manuals and user guides at all-guides.com INSP CONTROLE ET RECHARGE DE LA BATTERIE Méthode de charge à l’aide d’un chargeur à tension variable N.B.: Laisser reposer la batterie pendant Mesurer la tension en cir- 30 minutes avant de mesurer sa tension cuit ouvert avant de charger.
Página 291 All manuals and user guides at all-guides.com INSP CONTROLE ET RECHARGE DE LA BATTERIE Méthode de charge à l’aide d’un chargeur à tension constante N.B.: Mesurer la tension en circuit Laisser reposer batterie pendant 30 minutes avant de mesurer sa tension en ouvert avant de charger.
Página 292 All manuals and user guides at all-guides.com INSP BATTERIE KONTROLLIEREN UND LADEN Lademethode für ein Ladegerät mit konstanter Spannung HINWEIS: Vor dem Messen der Ruhespannung Vor dem Aufladen, die die Batterie über 30 Minuten lang Ruhespannung messen. nicht benutzen. Ladegerät Amperemeter HINWEIS: Ein Ladegerät und Ampe-...
Página 293 All manuals and user guides at all-guides.com INSP BATTERIE KONTROLLIEREN UND LADEN Lademethode für ein Ladegerät mit konstanter Spannung HINWEIS: Vor dem Aufladen die Vor dem Messen der Ruhespan- Ruhespannung messen. nung, die Batterie über 30 Minuten lang nicht benutzen. Ein Ladegerät und Ampe- remeter an die Batterie anschließen und mit dem...
Página 294: Inspección Y Carga De La Batería
All manuals and user guides at all-guides.com INSP INSPECCIÓN Y CARGA DE LA BATERÍA Método de carga con un cargador de voltaje variable NOTA: Mida el voltaje en circuito Deje la batería en reposo durante más de abierto antes de proceder a 30 minutos antes de medir el voltaje en Cargador circuito abierto.
Página 295 All manuals and user guides at all-guides.com INSP INSPECCIÓN Y CARGA DE LA BATERÍA Método de carga con un cargador de voltaje constante NOTA: Mida el voltaje en circuito Deje la batería en reposo durante más abierto antes de proceder a de 30 minutos antes de medir el voltaje la carga.
Página 296: Yu-3112-C/90890-03112
All manuals and user guides at all-guides.com INSP FUSE INSPECTION 6. Install: Battery Battery band 7. Connect: Battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1, then the negative lead 2. 8. Check: Battery terminals Dirt → Clean with a wire brush. Loose connection →...
Página 297 All manuals and user guides at all-guides.com INSPECTION DES FUSIBLES INSP SICHERUNGEN KONTROLLIEREN INSPECCIÓN DE LOS FUSIBLES 6. Montieren: Monter: Instalar: Batterie Batterie La batería Bandeau de batterie Batterieband Banda de la batería Connecter: 7. Anschließen: Conectar: Câbles fil de batterie Batteriekabel Los cables de la batería (aux bornes de la batterie)
Página 298: Replacing The Headlight Bulbs
All manuals and user guides at all-guides.com INSP REPLACING THE HEADLIGHT BULBS 3. Replace: Blown fuse Replacement steps: Set the main switch to “OFF”. Install a new fuse of the correct amperage. Set on the switches to verify if the electri- cal circuit is operational.
Página 299: Sustitución De Las Bombi- Llas Del Faro
All manuals and user guides at all-guides.com REMPLACER LES AMPOULES DU PHARE INSP SCHEINWERFERLAMPE AUSWECHSELN SUSTITUCIÓN DE LAS BOMBILLAS DEL FARO 3. Erneuern: Remplacer: Cambiar: Durchgebrannte Sicherung Fusible grillé Fusible fundido Etapes de remplacement: Arbeitsschritte: Pasos de sustitución: Das Zündschloß auf “OFF” stel- Placer le contacteur à...
Página 300: Adjusting The Headlight Beams
All manuals and user guides at all-guides.com INSP ADJUSTING THE HEADLIGHT BEAMS 5. Install: Headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the head- light bulb to keep it free form oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
Página 301: Scheinwerfer Einstellen
All manuals and user guides at all-guides.com REGLAGES DES FAISCEAUX DES PHARES INSP SCHEINWERFER EINSTELLEN AJUSTE DEL HAZ DE LUZ DEL FARO 5. Montieren: Installer: Instalar: Schweinwerferlampe Ampoule de phare Bombilla del faro Poser soigneusement la nou- Die neue Schweinwerfer- Asegure la nueva bombilla del velle ampoule de phare dans le lampe mit dem Lampenhal-...
Página 302: Seat, Fuel Tank And Side Covers
All manuals and user guides at all-guides.com SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS Extent of removal: 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Headlight removal Extent of removal Order Part name Q’ty...
Página 303 All manuals and user guides at all-guides.com SELLE, RESERVOIR A ESSENCE ET CACHES LATERAUX SITZBANK, KRAFTSTOFFTANK UND SEITENABDECKUNGEN ASIENTO, DEPÓSITO DE COMBUSTIBLE Y CUBIERTAS LATERALES MOTEUR SELLE, RESERVOIR A ESSENCE ET CACHES LATERAUX Organisation de la dépose: 1 Dépose du selle 2 Dépose du réservoir à...
Página 304 All manuals and user guides at all-guides.com SEAT, FUEL TANK AND SIDE COVERS REMOVAL POINTS Side cover 1. Remove: Bolt (side cover) Side cover (left) 1 Side cover (right) 2 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air fil- ter case.
Página 305: Puntos De Extracción
All manuals and user guides at all-guides.com SELLE, RESERVOIR A ESSENCE ET CACHES LATERAUX SITZBANK, KRAFTSTOFFTANK UND SEITENABDECKUNGEN ASIENTO, DEPÓSITO DE COMBUSTIBLE Y CUBIERTAS LATERALES AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Seitenabdeckung Cache latéral Cubierta lateral Déposer: 1. Demontieren: Extraer: Boulon (cache latéral) Schraube...
Página 306: Exhaust Pipe And Silencer
All manuals and user guides at all-guides.com EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER Å For USA ı 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...
Página 307: Tubo De Escape Y Silenciador
All manuals and user guides at all-guides.com TUYAU D’ECHAPPEMENT ET SILENCIEUX KRÜMMER UND SCHALLDÄMPFER TUBO DE ESCAPE Y SILENCIADOR TUYAU D’ECHAPPEMENT ET SILENCIEUX Å Pour l’USA ı Excepté pour l’USA Organisation de la dépose: 1 Dépose du silencieux 2 Dépose du tuyau d’échappement Organisation de la dépose Ordre Nom de pièce...
Página 308: Assembly And Installation
All manuals and user guides at all-guides.com EXHAUST PIPE AND SILENCER INSPECTION Exhaust pipe and silencer 1. Inspect: Gasket 1 Damage → Replace. ASSEMBLY AND INSTALLATION Exhaust pipe and silencer 1. Install: Gasket Exhaust pipe 1 Nut (exhaust pipe) 2 13 Nm (1.3 m ·...
Página 309 All manuals and user guides at all-guides.com TUYAU D’ECHAPPEMENT ET SILENCIEUX KRÜMMER UND SCHALLDÄMPFER TUBO DE ESCAPE Y SILENCIADOR PRÜFUNG CONTROLE INSPECCIÓN Krümmer und Schalldämpfer Tuyau d’echappement et silencieux Tubo de escape y silenciador Contrôler: 1. Kontrollieren: Inspeccionar: Joint 1 Dichtung 1 Junta 1 Endommagement →...
Página 310: Radiator
All manuals and user guides at all-guides.com RADIATOR EC450001 RADIATOR Extent of removal: 1 Radiator removal 2 Coolant reservoir 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.
Página 311 All manuals and user guides at all-guides.com RADIATEUR KÜHLER RADIADOR RADIATEUR Organisation de la dépose: 1 Dépose du radiateur 2 Dépose du réservoir de liquide de refroidissement Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU RADIATEUR Préparation à...
Página 312 All manuals and user guides at all-guides.com RADIATOR EC456000 HANDLING NOTE WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.
Página 313 All manuals and user guides at all-guides.com RADIATEUR KÜHLER RADIADOR HANDHABUNGSHINWEIS REMARQUES CONCERNANT LA NOTA DE MANEJO MANIPULATION WARNUNG ADVERTENCIA AVERTISSEMENT Der heiße Kühler steht unter No extraiga la tapa del radiador Ne jamais enlever le bouchon du Druck. Daher Kühlerver- cuando el motor y el radiador estén radiateur quand le moteur et le radia-...
Página 314 All manuals and user guides at all-guides.com RADIATOR 3. Install: Radiator breather hose 1 Radiator (right) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 4. Install: Panel 1 Bolt (radiator panel upper) 2 10 Nm (1.0 m ·...
Página 315 All manuals and user guides at all-guides.com RADIATEUR KÜHLER RADIADOR 3. Montieren: Monter: Instalar: Reniflard de radiateur 1 Kühler-Entlüftungsschlauch Tubo respiradero del radiador Radiateur (droit) 2 Kühler (rechts) 2 Radiador (derecho) 2 10 Nm (1,0 m · kg, 7,2 ft · lb) Se reporter à...
Página 316: Carburetor
All manuals and user guides at all-guides.com 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 •...
Página 317: Carburador
All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR CARBURATEUR Organisation de la dépose: 1 Dépose du carburateur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU CARBURATEUR Préparation à la dépose Réservoir à essence Se reporter à la section “SELLE, RESERVOIR A ESSENCE ET CACHES LATERAUX”.
Página 318 All manuals and user guides at all-guides.com CARBURETOR CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Cover Spring Diaphragm (accelerator pump)
Página 319: Desmontaje Del Carburador
All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR DEMONTAGE DU CARBURATEUR 1 Démontage du carburateur Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEMONTAGE DU CARBURATEUR Reniflard Couvercle de logement de levier de soupape Vis (axe d’accélérateur) Boisseau Support d’aiguille...
Página 320 All manuals and user guides at all-guides.com CARBURETOR Extent of removal Order Part name Q’ty Remarks Needle valve 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...
Página 321 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR Organisation de la dépose Ordre Nom de pièce Qté Remarques Pointeau Gicleur principal Gicleur de ralenti Entretoise Gicleur de starter Puits d’aiguille Tige de poussée Tirer la tige de commande. Ensemble de l’axe de papillon Ensemble du levier de timonerie de tige de commande...
Página 322 All manuals and user guides at all-guides.com CARBURETOR EC466020 HANDLING NOTE CAUTION: Do not loosen the screws {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance.
Página 323 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR HINWEIS ZUM HANDLING REMARQUE CONCERNANT LES NOTA DE MANEJO MANIPULATIONS ACHTUNG: ATENCION: ATTENTION: Die TPS-Schrauben (Drosselklap- No afloje los tornillos {TPS (sensor de Ne pas desserrer les vis {TPS (capteur pen-Positionssensor) 1 nicht lö- posición del acelerador)} 1 excepto du papillon d’accélération)} 1 sauf...
Página 324 All manuals and user guides at all-guides.com CARBURETOR Needle valve 1. Inspect: Needle valve 1 Valve seat 2 Grooved wear a → Replace. Dust b → Clean. EC464300 Throttle valve 1. Check: Free movement Stick → Repair or replace. Insert the throttle valve 1 into the car- buretor body, and check for free move- ment.
Página 325 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR Nadelventil Pointeau Válvula de aguja 1. Kontrollieren: Contrôler: Inspeccionar: Pointeau 1 Nadelventil 1 Válvula de aguja 1 Siège de pointeau 2 Ventilsitz 2 Asiento de la válvula 2 Usure creusée a → Changer. Desgaste con surcos a →...
Página 326 All manuals and user guides at all-guides.com CARBURETOR 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.
Página 327 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR Procédure de mesure et de réglage: Arbeitsschritte: Pasos de medición y ajuste: Mettre le carburateur à l’envers. Vergaser auf den Kopf stellen. Sujete el carburador con la parte de arriba hacia abajo. N.B.: HINWEIS: Den Vergaser langsam umdre-...
Página 328: Assembly And Installation
All manuals and user guides at all-guides.com CARBURETOR Accelerator pump 1. Inspect: Diaphragm (accelerator pump) 1 Spring 2 Cover 3 O-ring 4 Push rod 5 Tears (diaphragm)/damage → Replace. Dirt → Clean. 2. Inspect: Throttle shaft 1 Spring 2 Lever 1 3 Spring 1 4 Lever 2 5 Spring 2 6...
Página 329 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR Beschleunigungspumpe Pompe d’accélérateur Bomba de aceleración 1. Kontrollieren: Contrôler: Inspeccionar: Diaphragme (pompe d’accélé- Membran (Beschleuni- Diafragma (bomba de acelera- rateur) 1 gungspumpe) 1 ción) 1 Ressort 2 Feder 2 Muelle 2 Couvercle 3 Deckel 3 Cubierta 3...
Página 330 All manuals and user guides at all-guides.com 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.
Página 331 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR 3. Montieren: Installer: Instalar: Ressort 1 1 Feder 1 1 Resorte 1 1 Levier 1 2 Hebel 1 2 Palanca 1 2 Au levier 2 3. (zum Hebel 2 3) A palanca 2 3.
Página 332 All manuals and user guides at all-guides.com CARBURETOR 8. Install: 1 2 3 Throttle shaft assembly 1 Plain washer (metal) 2 Plain 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 TPS (throttle position sensor).
Página 333 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR 8. Montieren: Installer: Instalar: Ensemble d’axe de papillon 1 Drosselwellen-Baugruppe Conjunto del eje del acelera- Rondelle ordinaire (métal) 2 dor 1 Rondelle ordinaire (résine) 3 Unterlegscheibe (Metall) 2 Arandela plana (metal) 2 Culbuteur de soupape 4 Unterlegscheibe (Kunst- Arandela plana (resina) 3...
Página 334 All manuals and user guides at all-guides.com 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 Spring 2 Washer 3...
Página 335 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR 11. Montieren: 11. Monter: 11. Instalar: Pointeau 1 Nadelventil 1 Válvula de aguja 1 Flotteur 2 Schwimmer 2 Flotador 2 Axe de flotteur 3 Schwimmer-Achsstift 3 Bulón del flotador 3 HINWEIS: N.B.: NOTA:...
Página 336 All manuals and user guides at all-guides.com CARBURETOR 15. Install: Diaphragm (accelerator pump) 1 Spring 2 O-ring 3 Cover 4 Hose holder (drain hose) 5 Screw (cover) 6 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring. 16.
Página 337 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR 15. Montieren: 15. Monter: 15. Instalar: Membran (Beschleuni- Diaphragme (pompe d’accélé- Diafragma (bomba de acelera- rateur) 1 gungspumpe) 1 ción) 1 Ressort 2 Feder 2 Muelle 2 Joint torique 3 O-Ring 3 Junta tórica 3 Couvercle 4...
Página 338 All manuals and user guides at all-guides.com CARBURETOR Accelerator pump timing adjustment Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value.
Página 339 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR Beschleunigerpumpe-Zeitgabe- Réglage de l’injection de la pompe Ajuste de la sincronización de la einstellung d’accélérateur bomba de aceleración Etapes du réglage: Einstellschritte: Pasos de ajuste: N.B.: HINWEIS: NOTA: Um die Gasschieber-Höhe a auf Para poder poner la altura a de la Pour que la hauteur du papillon des gaz a soit à...
Página 340 All manuals and user guides at all-guides.com CARBURETOR 4. Tighten: Screw (air cleaner joint) 1 3 Nm (0.3 m · kg, 2.2 ft · lb) Screw (carburetor joint) 2 3 Nm (0.3 m · kg, 2.2 ft · lb) 5. Install: Throttle cable (pull) 1 4 Nm (0.4 m ·...
Página 341 All manuals and user guides at all-guides.com CARBURATEUR VERGASER CARBURADOR 4. Festziehen: Serrer: Apretar: Vis (raccord du filtre à air) 1 Schraube (Ansaugstutzen) Tornillo (junta del depurador del aire) 1 3 Nm (0,3 m · kg, 2,2 ft · lb) Vis (raccord du carburateur) 2 3 Nm (0,3 m ·...
Página 342: Camshafts
All manuals and user guides at all-guides.com CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER Extent of removal: 1 Cylinder head cover removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
Página 343: Arbres A Cames
All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ÁRBOLES DE LEVAS ARBRES A CAMES COUVERCLE DE CULASSE Organisation de la dépose: 1 Dépose du couvercle de culasse Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA CULASSE Préparation à...
Página 344 All manuals and user guides at all-guides.com CAMSHAFTS CAMSHAFTS Extent of removal: 1 Camshaft removal Extent of removal Order Part name Q’ty Remarks CAMSHAFTS REMOVAL Timing plug Straight plug Tensioner cap bolt Timing chain tensioner Gasket Refer to “REMOVAL POINTS”. Bolt (camshaft cap) Camshaft cap Clip...
Página 345 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ÁRBOLES DE LEVAS ARBRES A CAMES 1 Dépose de l’arbre à cames Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE L’ARBRE A CAMES Bouchon de distribution Bouchon droit Boulon capuchon du tendeur...
Página 346 All manuals and user guides at all-guides.com CAMSHAFTS REMOVAL POINTS Camshaft 1. Remove: Timing plug 1 Straight plug 2 2. Align: “I” mark With stationary pointer. Checking steps: Turn the crankshaft counterclockwise with a wrench. Align the “I” mark a on the rotor with the stationary pointer b on the crankcase cover.
Página 347: Puntos De Extracción
All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ÁRBOLES DE LEVAS AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Nockenwelle Arbre à cames Árbol de levas Déposer: 1. Demontieren: Extraer: Bouchon de distribution 1 Schwungrad-Abdeckschrau- Tapón de distribución 1 Bouchon droit 2 be 1 Tapón recto 2...
Página 348 All manuals and user guides at all-guides.com CAMSHAFTS 6. Remove: Clips 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 lobes Pitting/scratches/blue discoloration →...
Página 349: Inspección
All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ÁRBOLES DE LEVAS 6. Demontieren: Déposer: Extraer: Clip Clip de clavetage Clips Arbre à cames d’échappement Auslaß-Nockenwelle 1 Árbol de levas 1 (escape) Einlaß-Nockenwelle 2 Árbol de levas 2 (admisión) Arbre à...
Página 350 All manuals and user guides at all-guides.com CAMSHAFTS 4. Measure: Camshaft-to-cap clearance Out of specification → Measure cam- shaft journal diameter. Camshaft-to-cap clearance: 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: Install the camshaft onto the cylinder head.
Página 351 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ÁRBOLES DE LEVAS 4. Messen: Mesurer: Medir: Nockenwellen-Lagerspiel Jeu entre arbre à cames et cha- Holgura del árbol de levas a la Unvorschriftsmäßig → Den peau tapa Hors spécifications → Mesu- Fuera de especificaciones →...
Página 352: Assembly And Installation
All manuals and user guides at all-guides.com CAMSHAFTS Decompression system 1. Check: Decompression system Checking steps: Check that the decompressor cam 1 moves smoothly. Check that the decompressor lever pin 2 projects from the camshaft. Timing chain tensioner 1. Check: While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully...
Página 353 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ÁRBOLES DE LEVAS Dekompressionssystem Système de décompression Sistema de descompresión 1. Kontrollieren: Contrôler: Comprobar: Système de décompression Dekompressionssystem Sistema de descompresión Prüfschritte: Points à contrôler: Pasos de comprobación: Prüfen, ob der Dekompressi- S’assurer que la came de décom- Compruebe que la leva del des- presseur 1 tourne en douceur.
Página 354 All manuals and user guides at all-guides.com 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 exhaust cam sprocket punch mark c and the intake cam sprocket punch mark d align with the sur- face of the cylinder head.
Página 355 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ÁRBOLES DE LEVAS Die Steuerkette 3 auf beide Placer la chaîne de distribution 3 Coloque la cadena de distribución Nockenwellenräder legen und sur les deux pignons d’arbre à 3 en ambos piñones de árbol de die Nockenwellen am Zylinder- cames et installer les arbres à...
Página 356 All manuals and user guides at all-guides.com CAMSHAFTS With the rod fully wound and the chain ten- sioner UP mark a facing upward, install the gasket 1 and the chain tensioner 2, and tighten the bolt 3 to the specified torque.
Página 357 All manuals and user guides at all-guides.com ARBRES A CAMES NOCKENWELLE ÁRBOLES DE LEVAS Wenn der Spanner voll aufge- La tige complètement vissée et le Con la varilla completamente tor- dreht ist und die Markierung repère UP a du tendeur de chaîne cida y la marca UP a del tensor de “UP”...
Página 358: Cylinder Head
All manuals and user guides at all-guides.com 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”...
Página 359 All manuals and user guides at all-guides.com CULASSE ZYLINDERKOPF CULATA CULASSE CULASSE Organisation de la dépose: 1 Dépose de la culasse Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA CULASSE ET DU CYLINDRE Préparation à la dépose Selle et réservoir à...
Página 360 All manuals and user guides at all-guides.com CYLINDER HEAD INSPECTION Cylinder head 1. Eliminate: Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid dam- aging or scratching: Spark plug threads Valve seats 2.
Página 361 All manuals and user guides at all-guides.com CULASSE ZYLINDERKOPF CULATA PRÜFUNG CONTROLE INSPECCIÓN Zylinderkopf Culasse Culata Eliminer: 1. Entfernen: Eliminar: Dépôt de calamine Ölkohleablagerungen Depósitos de carbonilla (de las (de la chambre de combustion) Brennraum) cámaras de combustión) Utiliser un grattoir arrondi. Einen abgerundeten Scha- Utilice una rasqueta redon- ber verwenden.
Página 362 All manuals and user guides at all-guides.com CYLINDER HEAD ASSEMBLY AND INSTALLATION 1. Install: Timing chain guide (front) 1 Dowel pin 2 Cylinder head gasket 3 Cylinder head 4 NOTE: While pulling up the timing chain, install the timing chain guide (front) and cylinder head. 2.
Página 363 All manuals and user guides at all-guides.com CULASSE ZYLINDERKOPF CULATA ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAJE E INSTALACIÓN 1. Montieren: Monter: Instalar: Guide de chaîne de synchroni- Steuerkettenführung (vor- Guía de la cadena de distribu- sation (avant) 1 ne) 1 ción (delantera) 1 Cheville 2 Paßstift 2...
Página 364 All manuals and user guides at all-guides.com CYLINDER HEAD Remove the bolts. Again apply the molybdenum disulfide grease on the threads and contact sur- faces of the bolts and on both contact sur- faces of the plain washers. Retighten the bolts. NOTE: Tighten the bolts to the specified torque in two or three steps in the proper tightening...
Página 365 All manuals and user guides at all-guides.com CULASSE ZYLINDERKOPF CULATA Die Schrauben entfernen. Retirer les boulons. Quite los pernos. Molybdändisulfidfett ernaut auf Appliquer de la graisse de bisul- Aplique otra vez grasa de disulfato das Gewinde und die Kontakt- fure de molybdène sur les filets et de molibdeno a las roscas y super- flächen der Schrauben und auf les surfaces en contact des boulons...
Página 366: Valves And Valve Springs
All manuals and user guides at all-guides.com 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”...
Página 367: Ventile Und Ventilfedern
All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULA SOUPAPES ET RESSORTS DE SOUPAPE SOUPAPES ET RESSORTS DE SOUPAPE Organisation de la dépose: 1 Dépose de la soupape Organisation de la dépose Ordre Nom de pièce Qté...
Página 368: Valves And Valve Springs
All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS REMOVAL POINTS Valve lifter and valve cotter 1. Remove: Valve lifters 1 Pads 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place.
Página 369: Compresseur De Ressort De Soupape
All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULA POINTS DE DEPOSE AUSBAU PUNTOS DE EXTRACCIÓN Tassenstößel und Ventikeile Poussoir de soupape et clavette de sou- Empujadores de la válvula y chavetas pape 1.
Página 370 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS INSPECTION Valve 1. Measure: Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)
Página 371 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULA PRÜFUNG CONTROLE INSPECCIÓN Ventil Soupape Válvula Mesurer: 1. Messen: Medir: Jeu de queue dans le guide Ventilschaftspiel Holgura entre el vástago y la guía Ventilschaftspiel = Jeu de queue dans le guide de sou-...
Página 372: Ym-4116/90890-04116
All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS Valve guide remover: Intake: 4.5 mm (0.18 in) YM-4116/90890-04116 Exhaust: 5.0 mm (0.20 in) YM-4097/90890-04097 Valve guide installer: Intake: YM-4117/90890-04117 Exhaust: YM-4098/90890-04098 Valve guide reamer: Intake: 4.5 mm (0.18 in) YM-4118/90890-04118 Exhaust: 5.0 mm (0.20 in) YM-4099/90890-04099...
Página 373: Ym-4116/90890-04116
All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULA Outil de dépose du guide Ventilführungs-Austrei- Extractor de guías de vál- ber: de soupape: vula: Einlaß: 4,5 mm Admission: 4,5 mm Admisión: 4,5 mm (0,18 in) (0,18 in)
Página 374 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS 5. Measure: Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.0004 in) NOTE: When installing a new valve always replace the guide. If the valve is removed or replaced always replace the oil seal.
Página 375 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULA 5. Messen: Mesurer: Medir: Ventilschaftschlag Ovalisation (queue de soupape) Excentricidad (vástago de la Hors spécifications → Rempla- Unvorschriftsmäßig → válvula) Fuera de especificaciones →...
Página 376 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS 9. Lap: Valve face Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: Apply a coarse lapping compound to the valve face.
Página 377 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULA 9. Einschleifen: Roder: Esmerilar: Ventilteller Face de soupape Cara de la válvula Ventilsitz Siège de soupape Asiento de la válvula HINWEIS: N.B.: NOTA:...
Página 378 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS Valve spring 1. Measure: Valve spring free length a Out of specification → Replace. Free length (valve spring): Intake: 37.03 mm (1.46 in) <Limit>: 36.03 mm (1.42 in) Exhaust: 37.68 mm (1.48 in) <Limit>: 36.68 mm (1.44 in) 2.
Página 379 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULA Ventilfeder Ressort de soupape Muelle de la válvula 1. Messen: Mesurer: Medir: Longueur libre du ressort de Ventilfederlänge (ent- Longitud libre del muelle de la soupape a spannt) a válvula a...
Página 380: Assembly And Installation
All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS ASSEMBLY AND INSTALLATION 1. Apply: Molybdenum disulfide oil Onto the valve stem and valve stem seal. 2. Install: Valves 1 Valve spring seats 2 Valve stem seals 3 Valve springs 4 Valve spring retainers 5 NOTE: Make sure that each valve is installed in its...
Página 381 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULA ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAJE E INSTALACIÓN 1. Auftragen: Appliquer: Aplicar: Huile au bisulfure de molyb- Molybdändisulfidöl Aceite de disulfuro de molib- dène (auf Ventilschaft und Ventil- deno...
Página 382 All manuals and user guides at all-guides.com VALVES AND VALVE SPRINGS 5. Install: Adjusting pad 1 Valve lifter 2 NOTE: Apply the engine oil on the valve lifters. Apply the molybdenum disulfide oil on the valve stem end. Valve lifter must turn smoothly when rotated with a finger.
Página 383 All manuals and user guides at all-guides.com SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULA 5. Montieren: Monter: Instalar: Cales de réglage 1 Ventilplättchen 1 Suplemento de ajuste 1 Poussoir de soupape 2 Tassenstößel 2 Empujador de la válvula 2 HINWEIS: N.B.:...
Página 384: Cylinder And Piston
All manuals and user guides at all-guides.com 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”...
Página 385: Cylindre Et Piston
All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO Y PISTÓN CYLINDRE ET PISTON CYLINDRE ET PISTON Organisation de la dépose: 1 Dépose du cylindre 2 Dépose du piston Organisation de la dépose Ordre Nom de pièce Qté...
Página 386: Cylinder And Piston
All manuals and user guides at all-guides.com CYLINDER AND PISTON REMOVAL POINTS Piston 1. Remove: Piston pin clips 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.
Página 387: Yu-1304/90890-01304
All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO Y PISTÓN AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Kolben Piston Pistón Déposer: 1. Demontieren: Extraer: Agrafe d’axe de piston 1 Kolbenbolzen-Sicherungs- Circlips de los bulones de los Axe de piston 2 ringe 1 pistones 1...
Página 388 All manuals and user guides at all-guides.com CYLINDER AND PISTON 95.00 ~ 95.01 mm Cylinder bore “C” (3.7402 ~ 3.7406 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = Maximum D “T”...
Página 389 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO Y PISTÓN 95,00 à 95,00– 95,00 ~ Diámetro inte- Alésage de cylin- 95,01 mm Zylinderboh- 95,01 mm 95,01 mm rior del cilindro dre “C” (3,7402 à rung “C”...
Página 390 All manuals and user guides at all-guides.com CYLINDER AND PISTON Piston ring 1. Measure: Ring side clearance Use a feeler gauge 1. Out of specification → Replace the pis- ton and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance.
Página 391 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO Y PISTÓN Kolbenring Segment de piston Aro del pistón 1. Messen: Mesurer: Medir: Jeu latéral du segment Ringnutspiel Holgura lateral del aro Utiliser une jauge d’épaisseur Fühlerlehre 1 verwenden.
Página 392 All manuals and user guides at all-guides.com CYLINDER AND PISTON Piston pin 1. Inspect: Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: Piston pin-to-piston clearance Measurement steps: Measure the outside diameter (piston pin) If out of specification, replace the piston pin.
Página 393 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO Y PISTÓN Kolbenbolzen Axe de piston Bulón del pistón 1. Kontrollieren: Contrôler: Inspeccionar: Axe de piston Kolbenbolzen Bulón del pistón Décoloration bleue/gorges → Blaufärbung/Riefen → Coloración azul/ranuras → Remplacer puis examiner le Erneuern und Schmiersy- Reemplazar.
Página 394 All manuals and user guides at all-guides.com CYLINDER AND PISTON 2. Position: Top ring 2nd ring Oil ring 45° Offset the piston ring end gaps as 135° 135° shown. a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) 3.
Página 395 All manuals and user guides at all-guides.com CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO Y PISTÓN 2. Montieren: Positionner: Colocar: 1. Kompressionsring (To- Segment de feu Aro superior Segment d’étanchéité pring) Segundo aro Segment racleur d’huile 2. Kompressionsring Aro de engrase Décaler les becs de segment Ölabstreifring Distribuya de las separaciones...
Página 396: Clutch
All manuals and user guides at all-guides.com CLUTCH CLUTCH CLUTCH Extent of removal: 1 Push rod and push lever removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Clutch housing removal Extent of removal Order Part name Q’ty Remarks...
Página 397 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG EMBRAGUE EMBRAYAGE EMBRAYAGE Organisation de la dépose: 1 Dépose de la tige de commande et du levier de poussée 2 Démontage de la tige de commande 1 3 Dépose du disque de friction et du disque d’embrayage 4 Dépose du carter d’embrayage Organisation de la dépose Ordre...
Página 398 All manuals and user guides at all-guides.com CLUTCH Extent of removal Order Part name Q’ty Remarks Clutch plate Friction plate Use special tool. Look washer Refer to “REMOVAL POINTS”. Clutch boss Thrust washer Clutch housing Push lever 4 - 49...
Página 399 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG EMBRAGUE Organisation de la dépose Ordre Nom de pièce Qté Remarques Disque d’embrayage Disque de friction Ecrou Utiliser un outil spécial. Rondelle d’arrêt Se reporter à “POINTS DE DEPOSE”. Noix d’embrayage Rondelle de butée Cloche d’embrayage Levier de poussée...
Página 400: Ym-91042/90890-04086
All manuals and user guides at all-guides.com CLUTCH EC493000 REMOVAL POINTS EC483211 Clutch boss 1. Remove: Nut 1 Lock washer 2 Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. Å...
Página 401: Outil De Maintien D'embrayage
All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG EMBRAGUE AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Kupplungsnabe Noix d’embrayage Buje del embrague Déposer: 1. Demontieren: Extraer: Ecrou 1 Mutter 1 Tuerca 1 Rondelle-frein 2 Sicherungsscheibe 2 Arandela de freno 2 Noix d’embrayage 3 Kupplungsnabe 3 Buje del embrague 3...
Página 402 All manuals and user guides at all-guides.com CLUTCH EC484500 Friction plate 1. Measure: Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness: 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) <Limit>: 2.8 mm (0.110 in) EC484600 Clutch plate...
Página 403 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG EMBRAGUE Reibscheiben Disque de friction Disco de fricción 1. Messen: Mesurer: Medir: Epaisseur de disque de friction Reibscheibenstärke Espesor del disco de fricción Hors-spécification → Changer Unvorschriftsmäßig → Die Fuera de especificaciones → tous les disques de friction.
Página 404: Ym-91042/90890-04086
All manuals and user guides at all-guides.com CLUTCH EC4A5000 ASSEMBLY AND INSTALLATION Push lever 1. Install: Push lever 1 Bolt (push lever) 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the lithium soap base grease on the oil seal lip.
Página 405 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG EMBRAGUE ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAJE E INSTALACIÓN Druckhebel Levier de poussée Palanca de empuje Monter: 1. Montieren: Instalar: Levier de poussée 1 Druckhebel 1 Palanca de empuje 1 Boulon (levier de poussée) Schraube (Druckhebel) Perno (palanca de empuje)
Página 406 All manuals and user guides at all-guides.com CLUTCH 3. Bend the lock washer 1 tab. 4. Install: Friction plate 1 Clutch plate 2 NOTE: Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. Apply the engine oil on the friction plates and clutch plates.
Página 407 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG EMBRAGUE 3. Die Lasche der Sicherungs- Courber la languette de la ron- Doble la lengüeta de la arandela delle-frein 1. scheibe 1 umbiegen. de freno 1. Monter: 4. Montieren: Instalar: Disque de friction 1 Reibscheiben 1 Disco de fricción 1 Disque d’embrayage 2...
Página 408 All manuals and user guides at all-guides.com CLUTCH 8. Install: Clutch spring Bolt (clutch spring) 8 Nm (0.8 m · kg, 5.8 ft · lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 9. Install: Gasket (clutch cover) 1 Dowel pin 2 10.
Página 409 All manuals and user guides at all-guides.com EMBRAYAGE KUPPLUNG EMBRAGUE 8. Montieren: Monter: Instalar: Kupplungsfeder Ressort d’embrayage Muelle del embrague Boulon (ressort d’embrayage) Schraube (Kupplungsfeder) Perno (muelle del embrague) 8 Nm (0,8 m · kg, 5,8 ft · lb) 8 Nm (0,8 m · kg, 5,8 ft · lb) 8 Nm (0,8 m ·...
Página 410: Oil Filter, Water Pump And Crankcase Cover (Right)
All manuals and user guides at all-guides.com OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Extent of removal: 1 Oil filter removal 2 Water pump removal 3 Crankcase cover (right) removal Extent of removal Order...
Página 411: Ölfilter, Wasserpumpe Und Kurbelgehäusedeckel (Rechts)
All manuals and user guides at all-guides.com FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER (DROIT) ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL (RECHTS) FILTRO DE ACEITE, BOMBA DE AGUA Y CUBIERTA DEL CÁRTER (DERECHO) FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER (DROIT) FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER (DROIT) Organisation de la dépose: Dépose du filtre à...
Página 412 All manuals and user guides at all-guides.com OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Extent of removal Order Part name Q’ty Remarks Oil hose Kickstarter Crankcase cover (right) Gasket Dowel pin/O-ring Impeller Plain washer Impeller shaft Refer to “REMOVAL POINTS”. Oil seal 1 Oil seal 2 Bearing...
Página 413 All manuals and user guides at all-guides.com FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER (DROIT) ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL (RECHTS) FILTRO DE ACEITE, BOMBA DE AGUA Y CUBIERTA DEL CÁRTER (DERECHO) Organisation de la dépose Ordre Nom de pièce Qté...
Página 414 All manuals and user guides at all-guides.com OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) REMOVAL POINTS EC4G3110 Impeller shaft 1. Remove: Impeller 1 Plain washer 2 Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc.
Página 415 All manuals and user guides at all-guides.com FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER (DROIT) ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL (RECHTS) FILTRO DE ACEITE, BOMBA DE AGUA Y CUBIERTA DEL CÁRTER (DERECHO) AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Flügelradwelle Axe de turbine Eje del rodete...
Página 416 All manuals and user guides at all-guides.com OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) EC4H4600 Bearing 1. Inspect: Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. EC444400 Oil seal 1. Inspect: Oil seal Wear/damage → Replace. ASSEMBLY AND INSTALLATION EC4G5110 Oil seal...
Página 417 All manuals and user guides at all-guides.com FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER (DROIT) ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL (RECHTS) FILTRO DE ACEITE, BOMBA DE AGUA Y CUBIERTA DEL CÁRTER (DERECHO) Lager Roulement Cojinete 1. Kontrollieren: Contrôler: Inspeccionar: Roulement Lager...
Página 418 All manuals and user guides at all-guides.com OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) EC4G5220 Impeller shaft 1. Install: Impeller shaft 1 Plain washer 2 Impeller 3 14 Nm (1.4 m · kg, 10 ft · lb) NOTE: Take care so that the oil seal lip is not dam- aged or the spring does not slip off its posi- tion.
Página 419 All manuals and user guides at all-guides.com FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER (DROIT) ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL (RECHTS) FILTRO DE ACEITE, BOMBA DE AGUA Y CUBIERTA DEL CÁRTER (DERECHO) Flügelradwelle Axe de turbine Eje del rodete 1.
Página 420 All manuals and user guides at all-guides.com OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Kick crank 1. Install: Kickstarter 1 Plain washer Bolt (kickstarter) 33 Nm (3.3 m · kg, 24 ft · lb) NOTE: Install the kickstarter so that the distance a between the kickstarter and the fuel tank is 12 mm (0.47 in) or more.
Página 421 All manuals and user guides at all-guides.com FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER (DROIT) ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL (RECHTS) FILTRO DE ACEITE, BOMBA DE AGUA Y CUBIERTA DEL CÁRTER (DERECHO) Kickstarterhebel Démarreur au pied Manubrio del pedal 1.
Página 422 All manuals and user guides at all-guides.com OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) 2. Install: Water pump housing 1 Bolt (water pump housing) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) Plain washer 3 Coolant drain bolt 4 10 Nm (1.0 m ·...
Página 423 All manuals and user guides at all-guides.com FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER (DROIT) ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL (RECHTS) FILTRO DE ACEITE, BOMBA DE AGUA Y CUBIERTA DEL CÁRTER (DERECHO) 2. Montieren: Monter: Instalar: Wasserpumpengehäuse 1 Logement de la pompe à...
Página 424: Balancer
All manuals and user guides at all-guides.com BALANCER BALANCER BALANCER Extent of removal: 1 Balancer drive gear 2 Balancer Extent of removal Order Part name Q’ty Remarks BALANCER REMOVAL Preparation for removal Clutch housing Refer to “CLUTCH” section. Crankcase cover (right) Refer to “OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)”...
Página 425: Balancier Ausgleichswelle Compensador
All manuals and user guides at all-guides.com BALANCIER AUSGLEICHSWELLE COMPENSADOR BALANCIER BALANCIER Organisation de la dépose: 1 Pignon menant du balancier 2 Balancier Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU BALANCIER Préparation à la dépose Carter d’embrayage Se reporter à...
Página 426 All manuals and user guides at all-guides.com BALANCER REMOVAL POINTS Balancer drive gear and balancer driven gear 1. Straighten the lock washer tab. 2. Loosen: Nut (primary drive gear) 1 Nut (balancer) 2 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 3 and driven gear Balancer 1.
Página 427 All manuals and user guides at all-guides.com BALANCIER AUSGLEICHSWELLE COMPENSADOR AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Ausgleichswellen-Antriebs- und - Pignon menant et pignon mené du Engranaje de accionamiento del com- balancier Abtriebsräder pensador y engranaje impulsor del Redresser l’ongle de rondelle 1.
Página 428 All manuals and user guides at all-guides.com BALANCER ASSEMBLY AND INSTALLATION Balancer, balancer drive gear and balancer driven gear 1. Install: Balancer 1 NOTE: When installing the balancer shaft, align the center of the balancer shaft weight a along the line connecting the centers of the crank- shaft and balancer shaft.
Página 429 All manuals and user guides at all-guides.com BALANCIER AUSGLEICHSWELLE COMPENSADOR ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET INSTALLA- MONTAJE E INSTALACIÓN Ausgleichswelle, An- und TION Compensador, engranaje de acciona- Balancier, pignon menant de balan- Abtriebsrad miento del compensador y engranaje cier et pignon mené de balancier 1.
Página 430: Oil Pump
All manuals and user guides at all-guides.com 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 Clutch housing Refer to “CLUTCH”...
Página 431: Pompe A Huile
All manuals and user guides at all-guides.com POMPE A HUILE ÖLPUMPE BOMBA DE ACEITE POMPE A HUILE POMPE A HUILE Organisation de la dépose: 1 Dépose de la pompe à huile 2 Démontage de la pompe à huile Organisation de la dépose Ordre Nom de pièce Qté...
Página 432: Oil Pump
All manuals and user guides at all-guides.com OIL PUMP Extent of removal Order Part name Q’ty Remarks Washer Oil pump drive shaft Rotor housing 4 - 66...
Página 433 All manuals and user guides at all-guides.com POMPE A HUILE ÖLPUMPE BOMBA DE ACEITE Organisation de la dépose Ordre Nom de pièce Qté Remarques Goupille Rondelle Arbre de transmission de la pompe à huile Logement de rotor Reihen- Demontage-Arbeiten Bauteil Anz.
Página 434 All manuals and user guides at all-guides.com OIL PUMP INSPECTION Oil pump 1. Inspect: Oil pump drive gear Oil pump driven gear Rotor housing Oil pump cover Cracks/wear/damage → Replace. 2. Measure: Tip clearance a Between the inner rotor 1 and the outer rotor 2.
Página 435 All manuals and user guides at all-guides.com POMPE A HUILE ÖLPUMPE BOMBA DE ACEITE PRÜFUNG CONTROLE INSPECCIÓN Ôlpumpe Pompe à huile Bomba de aceite Contrôler: 1. Kontrollieren: Inspeccionar: Pignon menant de pompe à Ölpumpen-Antriebsrad Engranaje de accionamiento de huile Ölpumpen-Abtriebsrad la bomba de aceite Pignon mené...
Página 436 All manuals and user guides at all-guides.com OIL PUMP 2. Install: Outer rotor 1 1 NOTE: Apply the engine oil on the outer rotor 1. 3. Install: Oil pump cover 1 Screw (oil pump cover) 2 2 Nm (0.2 m · kg, 1.4 ft · lb) Pin 3 Inner rotor 2 4 Circlip 5...
Página 437 All manuals and user guides at all-guides.com POMPE A HUILE ÖLPUMPE BOMBA DE ACEITE 2. Montieren: Monter: Instalar: Rotor extérieur 1 1 Außenrotor 1 1 Rotor externo 1 1 HINWEIS: N.B.: NOTA: Motoröl auf den Außenrotor 1 auftra- Enduire le rotor extérieur 1 d’huile de Aplique aceite de motor en el rotor gen.
Página 438: Kick Axle And Shift Shaft
All manuals and user guides at all-guides.com KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT Extent of removal: 1 Kick axle removal 2 Kick axle disassembly 3 Shift shaft removal 4 Segment removal Extent of removal Order Part name...
Página 439 All manuals and user guides at all-guides.com AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR KICKSTARTERWELLE UND SCHALTWELLE EJE DEL PEDAL Y EJE DE SELECCIÓN AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR Organisation de la dépose: 1 Dépose de l’axe de démarreur au pied 2 Démontage de l’axe de démarreur au pied...
Página 440 All manuals and user guides at all-guides.com KICK AXLE AND SHIFT SHAFT Extent of removal Order Part name Q’ty Remarks 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”.
Página 441 All manuals and user guides at all-guides.com AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR KICKSTARTERWELLE UND SCHALTWELLE EJE DEL PEDAL Y EJE DE SELECCIÓN Organisation de la dépose Ordre Nom de pièce Qté Remarques Rouleau Guide de sélecteur Se reporter à...
Página 442 All manuals and user guides at all-guides.com KICK AXLE AND SHIFT SHAFT REMOVAL POINTS EC4B3101 Kick axle assembly 1. Remove: Kick axle assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1.
Página 443 All manuals and user guides at all-guides.com AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR KICKSTARTERWELLE UND SCHALTWELLE EJE DEL PEDAL Y EJE DE SELECCIÓN AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Kickstarterwelle (komplett) Ensemble axe de démarreur au pied Conjunto del eje del pedal Déposer: 1.
Página 444 All manuals and user guides at all-guides.com KICK AXLE AND SHIFT SHAFT EC4B4400 Shift shaft 1. Inspect: Shift shaft 1 Bend/damage → Replace. Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4...
Página 445 All manuals and user guides at all-guides.com AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR KICKSTARTERWELLE UND SCHALTWELLE EJE DEL PEDAL Y EJE DE SELECCIÓN Schaltwelle Arbre de sélecteur Eje de selección 1. Kontrollieren: Contrôler: Inspeccionar: Arbre de sélecteur 1 Schaltwelle 1 Eje de selección 1 Tordu/endommagement →...
Página 446 All manuals and user guides at all-guides.com KICK AXLE 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.
Página 447 All manuals and user guides at all-guides.com AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR KICKSTARTERWELLE UND SCHALTWELLE EJE DEL PEDAL Y EJE DE SELECCIÓN Rastenhebel Levier de butée Palanca tope 1. Montieren: Monter: Instalar: Ressort de torsion 1 Torsionsfeder 1 Resorte de torsión 1 Levier de butée 2...
Página 448 All manuals and user guides at all-guides.com KICK AXLE AND SHIFT SHAFT EC4C5301 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 Refer to “AC MAGNETO AND STARTER CLUTCH”...
Página 449 All manuals and user guides at all-guides.com AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR KICKSTARTERWELLE UND SCHALTWELLE EJE DEL PEDAL Y EJE DE SELECCIÓN Schaltwelle Arbre de sélecteur Eje de selección 1. Montieren: Monter: Instalar: Roulement 1 Rolle 1 Rodillo 1 Collerette 2 Distanzhülse 2...
Página 450 All manuals and user guides at all-guides.com KICK AXLE AND SHIFT SHAFT 3. Install: 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.
Página 451 All manuals and user guides at all-guides.com AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR KICKSTARTERWELLE UND SCHALTWELLE EJE DEL PEDAL Y EJE DE SELECCIÓN 3. Montieren: Monter: Instalar: Guide de ressort 1 Federsitz 1 Guía del resorte 1 HINWEIS: N.B.: NOTA:...
Página 452: Ac Magneto And Starter Clutch
All manuals and user guides at all-guides.com AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH Extent of removal: 1 Starter clutch/wheel gear removal 2 Rotor removal 3 Pickup coil/stator removal Extent of removal Order Part name Q’ty Remarks AC MAGNETO AND STATOR REMOVAL Preparation for removal...
Página 453: Magneto De Ca Y Embrague Del Arrancador
All manuals and user guides at all-guides.com MAGNÉTO CA ET ROCHET DE DÉMARRAGE AC-MAGNETZÜNDER UND STARTERKUPPLUNG MAGNETO DE CA Y EMBRAGUE DEL ARRANCADOR MAGNÉTO CA ET ROCHET DE DÉMARRAGE Organisation de la dépose: 1 Dépose du rochet de démarrage/pignon de roue 2 Dépose du rotor 3 Dépose de la bobine d’excitation/stator Organisation de la dépose...
Página 454: Ac Magneto And Starter Clutch
All manuals and user guides at all-guides.com AC MAGNETO AND STARTER CLUTCH Extent of removal Order Part name Q’ty Remarks Dowel pin Idle gear Bearing Shaft Nut (rotor) Refer to NOTE. Rotor Use special tool. Refer to “REMOVAL POINTS”. Woodruff key Starter clutch Starter clutch drive gear Holder...
Página 455 All manuals and user guides at all-guides.com MAGNÉTO CA ET ROCHET DE DÉMARRAGE AC-MAGNETZÜNDER UND STARTERKUPPLUNG MAGNETO DE CA Y EMBRAGUE DEL ARRANCADOR Organisation de la dépose Ordre Nom de pièce Qté Remarques Goujon Pignon de ralenti Roulement Ecrou (rotor) Se reporter à...
Página 456: Ys-1880-A/90890-01701
All manuals and user guides at all-guides.com AC MAGNETO AND STARTER CLUTCH EC4L3000 REMOVAL POINTS Rotor 1. Remove: Nut (rotor) 1 Plain washer Use the sheave holder 2. Sheave holder: YS-1880-A/90890-01701 2. Remove: Rotor 1 Use the rotor puller 2. Rotor puller: YM-04142/90890-04142 EC4L4000...
Página 457: Clé À Sangle
All manuals and user guides at all-guides.com MAGNÉTO CA ET ROCHET DE DÉMARRAGE AC-MAGNETZÜNDER UND STARTERKUPPLUNG MAGNETO DE CA Y EMBRAGUE DEL ARRANCADOR AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Rotor Rotor Rotor Déposer: 1. Demontieren: Extraer: Ecrou (rotor) 1 Mutter (Rotor) 1 Tuerca (rotor) 1 Rondelle ordinaire...
Página 458: Assembly And Installation
All manuals and user guides at all-guides.com AC MAGNETO AND STARTER CLUTCH Starter clutch 1. Check: Starter clutch Damage/wear → Replace. 2. Check: Idle gear Idle gear shaft Starter clutch gear → Pitting/burrs/chips/roughness/wear Replace the defective parts. 3. Check: Starter clutch operation Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch.
Página 459 All manuals and user guides at all-guides.com MAGNÉTO CA ET ROCHET DE DÉMARRAGE AC-MAGNETZÜNDER UND STARTERKUPPLUNG MAGNETO DE CA Y EMBRAGUE DEL ARRANCADOR Starterkupplung Rochet de démarrage Embrague del arrancador 1. Prüfen: Inspecter: Comprobar: Rochet de démarrage Starterkupplung Embrague del arrancador Endommagé/usé...
Página 460 Apply the sealant to the grommet of the AC magneto lead.  Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 3. Install: Starter clutch drive gear 1 Starter clutch 2 NOTE: Apply the engine oil on the starter clutch drive gear inner circumference.
Página 461 Das Dichtmittel auf die Tülle der del magneto de CA. AC-Magnetzünderleitung auftra- Quick gasket ® gen. ACC-QUICK-GS-KT YAMAHA bond n˚1215: ® Quick gasket 90890-85505 ACC-QUICK-GS-KT ® Quick gasket Adhesivo YAMAHA ACC-QUICK-GS-KT N˚1215: YAMAHA-Dichtmasse 90890-85505 Nr.
Página 462: Ys-1880-A/90890-01701
All manuals and user guides at all-guides.com AC MAGNETO AND STARTER CLUTCH 5. Install: Bolt (starter clutch) 1 16 Nm (1.6 m · kg, 11 ft · lb) Plain washer (rotor) Nut (rotor) 2 65 Nm (6.5 m · kg, 47 ft · lb) Use the sheave holder 3.
Página 463 All manuals and user guides at all-guides.com MAGNÉTO CA ET ROCHET DE DÉMARRAGE AC-MAGNETZÜNDER UND STARTERKUPPLUNG MAGNETO DE CA Y EMBRAGUE DEL ARRANCADOR 5. Montieren: Installer: Instalar: Steckschraube (Starter- Boulon (rochet de démarrage) Perno (embrague del arranca- kupplung) 1 dor) 1 16 Nm (1,6 m ·...
Página 464 All manuals and user guides at all-guides.com AC MAGNETO AND STARTER CLUTCH 9. Install: Cover (idle gear 1) 1 Bolt 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Install the cover (idle gear 1) with its mark a facing upward.
Página 465 All manuals and user guides at all-guides.com MAGNÉTO CA ET ROCHET DE DÉMARRAGE AC-MAGNETZÜNDER UND STARTERKUPPLUNG MAGNETO DE CA Y EMBRAGUE DEL ARRANCADOR 9. Montieren: Installer: Instalar: Abdeckung (Leerlaufrad 1) Couvercle (pignon de ralenti 1) Cubierta (engranaje de ralentí 1) 1 Boulon 2 Steckschraube 2 Perno 2...
Página 466: Engine Removal
All manuals and user guides at all-guides.com ENGINE REMOVAL EC4M0000 ENGINE REMOVAL Extent of removal Order Part name Q’ty Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the WARNING suitable stand under the frame. Support the machine securely so there is no danger of it falling over.
Página 467: Depose Du Moteur
All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN EXTRACCIÓN DEL MOTOR DEPOSE DU MOTEUR Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU MOTEUR AVERTISSEMENT Préparation à la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas de approprié...
Página 468 All manuals and user guides at all-guides.com ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Order Part name Q’ty Remarks Crankcase cover (left) Refer to “AC MAGNETO AND STARTER CLUTCH” section for remov- ing the starter motor lead. Disconnect the starter motor Refer to “ELECTRIC STARTING SYS- lead.
Página 469 All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN EXTRACCIÓN DEL MOTOR 1 Dépose du moteur Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques Couvercle de carter (gauche) Se reporter à la section “Magnéto CA et Embrayage de démarreur”...
Página 470 All manuals and user guides at all-guides.com ENGINE REMOVAL Extent of removal Order Part name Q’ty Remarks Engine upper bracket (right) Engine upper bracket (left) Engine lower bracket Engine mounting bolt Pivot shaft Refer to “REMOVAL POINTS”. Engine 4 - 85...
Página 471 All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN EXTRACCIÓN DEL MOTOR Organisation de la dépose Ordre Nom de pièce Qté Remarques Support supérieur du moteur (droite) Support supérieur du moteur (gauche) Support inférieur du moteur Boulon de montage du moteur Axe de pivot Se reporter à...
Página 472 All manuals and user guides at all-guides.com ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: Nut (drive sprocket) 1 Lock washer 2 NOTE: Straighten the lock washer tab. Loosen the nut while applying the rear brake. 2. Remove: Drive sprocket 1 Drive chain 2 NOTE:...
Página 473 All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN EXTRACCIÓN DEL MOTOR AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Antriebsritzel Pignon d’entraînement Piñón de accionamiento Déposer: 1. Demontieren: Extraer: Ecrou (pignon d’entraînement) Mutter (Antriebsritzel) 1 Tuerca (piñón de acciona- Sicherungsscheibe 2 miento) 1 Rondelle-frein 2...
Página 474: Assembly And Installation
All manuals and user guides at all-guides.com ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1. Install: Engine 1 Install the engine from right side. Pivot shaft 2 85 Nm (8.5 m · kg, 61 ft · lb) Engine mounting bolt (lower) 3 69 Nm (6.9 m ·...
Página 475 All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN EXTRACCIÓN DEL MOTOR ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAJE E INSTALACIÓN Montage du moteur Instalación del motor Motor montieren Monter: Instalar: 1. Montieren: Moteur 1 Motor 1 Motor 1 Monter le moteur par le côté...
Página 476 All manuals and user guides at all-guides.com ENGINE REMOVAL Drive sprocket 1. Install: Drive sprocket 1 Drive chain 2 NOTE: Install the drive sprocket together with the drive chain. 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.
Página 477 All manuals and user guides at all-guides.com DEPOSE DU MOTEUR MOTOR DEMONTIEREN EXTRACCIÓN DEL MOTOR Antriebsritzel Pignon d’entraînement Piñón de accionamiento 1. Montieren: Monter: Instalar: Pignon d’entraînement 1 Antriebsritzel 1 Piñón de accionamiento 1 Chaîne de transmission 2 Antriebskette 2 Cadena de transmisión 2 HINWEIS: N.B.:...
Página 478: Crankcase And Crankshaft
All manuals and user guides at all-guides.com 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 SEPARATION Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON”...
Página 479: Kurbelgehäuse Und Kurbelwelle
All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL CARTER ET VILEBREQUIN CARTER ET VILEBREQUIN Organisation de la dépose: 1 Séparation du carter 2 Dépose du carter d’huile Organisation de la dépose Ordre Nom de pièce Qté...
Página 480: Crankcase And Crankshaft
All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q’ty Remarks Oil strainer Oil delivery pipe 2 Crankshaft Use special tool. Refer to “REMOVAL POINTS”. 4 - 90...
Página 481 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL Organisation de la dépose Ordre Nom de pièce Qté Remarques Carter d’huile Tuyau d’arrivée d’huile 2 Vilebrequin Utiliser l’outil spécial. Se reporter à “POINTS DE DEPOSE”. Reihen- Demontage-Arbeiten Bauteil...
Página 482 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT CRANKCASE BEARING Extent of removal: 1 Crankcase bearing removal Extent of removal Order Part name Q’ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to “TRANSMISSION, SHIFT Shift cam and shift fork CAM AND SHIFT FORK”...
Página 483: Roulements De Carter
All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL ROULEMENTS DE CARTER 1 Depose des roulements de carter Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DES ROULEMENTS DE CAR- Préparation à...
Página 484 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT REMOVAL POINTS Crankcase 1. Separate: Crankcase (right) Crankcase (left) Separation steps: Remove the crankcase bolts, hose guide and clutch cable holder. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.
Página 485 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Kurbelgehäuse Carter Cárter Séparer: 1. Trennen: Separar: Demi-carter (droit) Kurbelgehäusehälfte Cárter (derecho) Demi-carter (gauche) (rechts) Cárter (izquierdo) Kurbelgehäusehälfte (links) Etapes de la séparation: Pasos de separación:...
Página 486: Yu-1135-A/90890-01135
All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT Crankshaft 1. Remove: Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 CAUTION: Do not use a hammer to drive out the crankshaft. Crankshaft bearing 1. Remove: Bearing 1 NOTE: Remove the bearing from the crankcase by...
Página 487: Outil De Séparation De Carter
All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL Kurbelwelle Vilebrequin Cigüeñal 1. Demontieren: Déposer: Extraer: Vilebrequin 1 Kurbelwelle 1 Cigüeñal 1 Utiliser le séparateur de carter Das Kurbelgehäuse-Trenn- Utilice la herramienta de sepa- werkzeug 2.
Página 488: Dial Gauge And Stand
All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1. Measure: Runout limit a Small end free play limit b Connecting rod big end side clearance Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge.
Página 489: Yu-3097/90890-01252
All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL Kurbelwelle Vilebrequin Cigüeñal 1. Messen: Mesurer: Medir: Limite de faux-rond a Schlaggrenze a Límite de excentricidad a Pleuel-Radialspiel b Limite de déflexion de pied de Límite del juego libre del pie bielle b Pleuel-Axialspiel c...
Página 490: Assembly And Installation
All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankshaft bearing 1. Install: Bearing Bearing stopper Bolt (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) Screw (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) Screw [bearing stopper (crankshaft)] 1 10 Nm (1.0 m ·...
Página 491: Yu-90050/90890-01274
All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAJE E INSTALACIÓN Kurbelwellenlager Roulement de vilebrequin Cojinete del cigüeñal 1. Einbauen: Installer: Instalar: Roulement Lager Cojinete Lageranschlag Butoir de roulement Tope del cojinete Schraube (Lageranschlag)
Página 492 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Apply: Sealant On the crankcase (right) 1. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 NOTE: Clean the contacting surface of crankcase (left and right) before applying the sealant. 4 - 96...
Página 493 Quick gasket ® ® Quick gasket ® Quick gasket ACC-QUICK-GS-KT ACC-QUICK-GS-KT ACC-QUICK-GS-KT YAMAHA-Dichtmasse Adhesivo YAMAHA YAMAHA bond n˚1215: Nr. 1215: N˚ 1215: 90890-85505 90890-85505 90890-85505 N.B.: HINWEIS: NOTA: Nettoyer la surface de contact des demi- Vor dem Auftragen der Dichtmasse Limpie las superficies de contacto del carters (gauche et droit) avant d’appli-...
Página 494 All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT 5. Install: Dowel pin 1 O-ring 2 Crankcase (right) To crankcase (left). NOTE: Fit the crankcase (right) onto the crankcase (left). Tap lightly on the case with soft ham- mer. When installing the crankcase, the connect- ing rod should be positioned at TDC (top dead center).
Página 495 All manuals and user guides at all-guides.com CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL 5. Montieren: Monter: Instalar: Goujon 1 Paßstift 1 Fijo de centraje 1 Joint torique 2 O-Ring 2 Junta tórica 2 Demi-carter (droit) Kurbelgehäusehälfte Cárter (derecho) Vers le demi-carter (gauche).
Página 496: Transmission, Shift Cam And Shift Fork
All manuals and user guides at all-guides.com TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK 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...
Página 497: Getriebe, Schaltwalze Und Schaltgabeln
All manuals and user guides at all-guides.com BOITE A VITESSES, TAMBOUR ET FOURCHETTE DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE SELECCIÓN Y HORQUILLA DE SELECCIÓN BOITE A VITESSES, TAMBOUR ET FOURCHETTE DE SELECTION BOITE A VITESSES, TAMBOUR, FOURCHETTE DE SELECTION ET VILEBREQUIN Organisation de la dépose: 1 Dépose de la fourchette de sélection, de l’arbre à...
Página 498: Transmission, Shift Cam And Shift Fork
All manuals and user guides at all-guides.com TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS Shift fork, shaft cam and transmission 1. Remove: Shift forks Shift cam Main axle Drive axle NOTE: Tap lightly on the transmission drive axle and shift cam with a soft hammer to remove.
Página 499 All manuals and user guides at all-guides.com BOITE A VITESSES, TAMBOUR ET FOURCHETTE DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE SELECCIÓN Y HORQUILLA DE SELECCIÓN AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Schaltgabeln, Schaltwalze und Fourchette de sélection, tambour et Horquilla de selección, leva de selec- boîte à...
Página 500 All manuals and user guides at all-guides.com TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4801 Shift fork, shift cam and segment 1. Inspect: Shift fork 1 Wear/damage/scratches → Replace. 2. Inspect: Shift cam 1 Segment 2 Bend/wear/damage → Replace. 3. Check: Shift fork movement Unsmooth operation →...
Página 501 All manuals and user guides at all-guides.com BOITE A VITESSES, TAMBOUR ET FOURCHETTE DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE SELECCIÓN Y HORQUILLA DE SELECCIÓN Schaltgabeln und Schaltwalze Fourchette, tambour et barillet Horquilla de selección, leva de selec- 1.
Página 502 All manuals and user guides at all-guides.com TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: 2nd wheel gear (26T) 1 4th wheel gear (21T) 2 3rd wheel gear (21T) 3 5th wheel gear (21T) 4 1st wheel gear (29T) 5 O-ring 6 To drive axle 7.
Página 503 All manuals and user guides at all-guides.com BOITE A VITESSES, TAMBOUR ET FOURCHETTE DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE SELECCIÓN Y HORQUILLA DE SELECCIÓN 2. Montieren: Monter: Instalar: Pignon de 2ème (26D) 1 Zahnrad 2. Gang (26 Zäh- Engranaje de 2ª...
Página 504 All manuals and user guides at all-guides.com TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: Shift fork 1 (L) 1 Shift fork 2 (C) 2 Shift fork 3 (R) 3 Shift cam 4 To main axle and drive axle. NOTE: Apply the molybdenum disulfide oil on the shift fork grooves.
Página 505 All manuals and user guides at all-guides.com BOITE A VITESSES, TAMBOUR ET FOURCHETTE DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE SELECCIÓN Y HORQUILLA DE SELECCIÓN 5. Montieren: Monter: Instalar: Fourchette 1 (L) 1 Schaltgabel 1 (L) 1 Horquilla de selección 1 (L) 1 Fourchette 2 (C) 2 Schaltgabel 2 (C) 2...
Página 506: Chassis
All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL Extent of removal: 1 Front wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty...
Página 507: Rueda Delantera Y Rueda Trasera
All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE ROUE AVANT 1 Dépose de la roue avant 2 Dépose du roulement de roue Organisation de la dépose: 3 Dépose du disque de frein Organisation de la dépose...
Página 508: Rear Wheel Removal
All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL Extent of removal: 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks REAR WHEEL REMOVAL WARNING Preparation for removal Hold the machine by placing the...
Página 509: Roue Arriere
All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA ROUE ARRIERE 1 Dépose de la roue arrière 2 Dépose du roulement de roue Organisation de la dépose: 3 Dépose du disque de frein Organisation de la dépose Ordre Nom de pièce...
Página 510 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: Bearing 1 NOTE: Remove the bearing using a general bearing...
Página 511 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Hinterrad Roue arrière Rueda trasera Déposer: 1. Demontieren: Extraer: Roue 1 Rad 1 Rueda 1 HINWEIS: N.B.:...
Página 512 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: Wheel axle bends Out of specification → Replace. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading.
Página 513 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA Radachse Axe de roue Eje de la rueda 1. Messen: Mesurer: Medir: Les flexions de l’axe de roue Radachsschlag Deformaciones del eje de la Hors-spécification →...
Página 514: Assembly And Installation
All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION Front wheel 1. Install: Bearing (left) 1 Spacer 2 Bearing (right) 3 Oil seal 4 NOTE: Apply the lithium soap base grease on the bearing and oil seal lip when installing.
Página 515 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAJE E INSTALACIÓN Vorderrad Roue avant Rueda delantera Monter: 1. Montieren: Instalar: Roulement (gauche) 1 Lager (links) 1 Cojinete (izquierdo) 1 Entretoise 2...
Página 516 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL 5. Install: Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly. Make sure that the projections a in the trip meter gear unit fits over the stopper b on the front fork outer tube.
Página 517 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA 5. Montieren: Monter: Instalar: Roue Rueda HINWEIS: N.B.: NOTA: Die Bremsscheibe 1 zwischen die Reposer correctement le disque du Instale el disco del freno 1 correcta- frein 1 entre les plaquettes de frein Bremsbeläge 2 führen.
Página 518 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL 8. Tighten: Bolt (axle holder) 1 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork sev- eral times with the front brake applied.
Página 519 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA 8. Festziehen: Serrer: Apretar: Boulon (support d’axe) 1 Schraube (Achshalterung) 1 Perno (soporte del eje) 1 23 Nm (2,3 m · kg, 17 ft · lb) 23 Nm (2,3 m ·...
Página 520 All manuals and user guides at all-guides.com 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. Install the bearing with seal facing outward.
Página 521 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA Hinterrad Roue arrière Rueda trasera 1. Montieren: Monter: Instalar: Roulement (droit) 1 Lager (rechts) 1 Cojinete (derecho) 1 Circlip 2 Sicherungsring 2 Circlip 2 Entretoise 3...
Página 522 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL 4. Install: Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip. 5. Install: Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly.
Página 523 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA 4. Montieren: Monter: Instalar: Collerette 1 Hülse 1 Casquillo 1 HINWEIS: N.B.: NOTA: Lithiumfett auf die Dichtlippe des Enduire la lèvre de la bague d’étanchéité Aplique grasa a base de jabón de litio en Wellendichtrings auftragen.
Página 524 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND REAR WHEEL 9. Adjust: Drive chain slack a Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 in) Refer “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAP- TER 3. 10.
Página 525 All manuals and user guides at all-guides.com ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA 9. Einstellen: Régler: Ajustar: Antriebsketten-Durchhang Flèche de chaîne de transmis- Tensión de la cadena de trans- sion a misión a Antriebsketten-Durch- Flèche de chaîne de trans- Tensión de la cadena de...
Página 526: Front Brake And Rear Brake
All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 2 Caliper removal 3 Master cylinder removal Extent of removal Order Part name Q’ty Remarks...
Página 527: Frein Avant Et Frein Arriere
All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO FREIN AVANT ET FREIN ARRIERE FREIN AVANT Organisation de la dépose: 1 Dépose du tuyau de frein 2 Dépose de l’étrier 3 Dépose du maître-cylindre Organisation de la dépose Ordre...
Página 528: Front Brake And Rear Brake
All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE Extent of removal: 1 Master cylinder removal 2 Brake hose removal 3 Caliper removal Extent of removal Order Part name Q’ty Remarks REAR BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the...
Página 529: Freno Trasero
All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO FREIN ARRIERE 1 Dépose du maître-cylindre 2 Dépose du tuyau de frein Organisation de la dépose: 3 Dépose de l’étrier Organisation de la dépose Ordre Nom de pièce...
Página 530 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE EC5A8200 CALIPER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front caliper disassembly 2 Rear caliper disassembly Extent of removal Order Part name Q’ty Remarks CALIPER DISASSEMBLY Pad pin Brake pad Pad support...
Página 531: Desmontaje Del Caliper
All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS RUEDA DELANTERA Y RUEDA TRASERA DEMONTAGE DE L’ETRIER Å Avant ı Arrière Organisation de la dépose: 1 Démontage de l’étrier avant 2 Démontage de l’étrier arrière Organisation de la dépose Ordre Nom de pièce...
Página 532 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE EC5A8300 MASTER CYLINDER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front master cylinder disassembly 2 Rear master cylinder disassembly Extent of removal Order Part name Q’ty Remarks MASTER CYLINDER DISAS-...
Página 533: Desmontaje Del Cilindro Principal
All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO DEMONTAGE DU MAITRE-CYLINDRE Å Avant ı Arrière Organisation de la dépose: 1 Démontage du maître-cylindre avant 2 Démontage du maître-cylindre arrière Organisation de la dépose Ordre Nom de pièce...
Página 534 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 Å REMOVAL POINTS Brake fluid 1. Remove: [Front] Master cylinder cap 1 [Rear] Master cylinder cap 1 Protector NOTE: Do not remove the diaphragm. ı Å Front ı...
Página 535 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Bremsflüssigkeit Liquide de frein Líquido de frenos Déposer: 1. Demontieren: Extraer: [Arrière] [Vorn] [Delantero] Capuchon du maître-cylindre...
Página 536 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE EC533402 Å Piston seal kit 1. Remove: Dust seal 1 Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: ı...
Página 537 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO Bremskolben-Dichtringe Kit de joint de piston Juego del retén del pistón 1. Demontieren: Déposer: Extraer: Joint antipoussière 1 Staubschutzring 1 Guardapolvos 1 Joint de piston 2 Dichtring 2...
Página 538: Assembly And Installation
All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 4. Inspect: Å ı Master cylinder piston 1 Master cylinder cup 2 Wear/damage/score marks → Replace master cylinder kit. Å Front ı Rear EC534214 Å ı Caliper 1.
Página 539 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO 4. Kontrollieren: Contrôler: Inspeccionar: Piston du maître-cylindre 1 Bremskolben 1 Pistón del cilindro principal 1 Capuchon du maître-cylindre Hauptbremszylinder-Man- Tapa del cilindro principal 2 schette 2 Desgaste/daños/marcas...
Página 540 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE EC5A5800 Å Caliper piston 1. Clean: Caliper Piston seal Dust seal Caliper piston Clean them with brake fluid. 2. Install: Piston seal 1 Dust seal 2 ı WARNING Always use new piston seals and dust seals.
Página 541 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO Bremskolben Piston d’étrier Pistón del caliper 1. Reinigen: Nettoyer: Limpiar: Etrier Bremssattel Caliper Joint de piston Dichtring Retén del pistón Joint antipoussière Staubschutzring Guardapolvos...
Página 542 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Copper washer 1 Union bolt 2 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe por- tion a directs as shown and lightly touches the projection b on the caliper.
Página 543 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO 2. Montieren: Monter: Instalar: Rondelle en cuivre 1 Kupferscheibe 1 Arandela de cobre 1 Boulon-raccord 2 Hohlschraube 2 Perno de unión 2 30 Nm (3,0 m ·...
Página 544 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Disc cover 1 Bolt (disc cover) 2 7 Nm (0.7 m · kg, 5.1 ft · lb) 3. Install: Caliper 1 Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL”...
Página 545 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO 2. Montieren: Monter: Instalar: Couvercle de disque 1 Scheibenabdeckung 1 Cubierta del disco 1 Boulon (couvercle de disque) 2 Steckschraube (Scheiben- Perno (cubierta del disco) 2 abdeckung) 2...
Página 546 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 3. Install: Å ı Spring 1 To master cylinder piston 2. NOTE: Install the spring at the smaller dia. side. Å Front ı Rear 4. Install: Å [Front] Master cylinder kit 1 Plain washer 2...
Página 547 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO 3. Montieren: Monter: Instalar: Ressort 1 Feder 1 Resorte 1 Au piston de maître-cylindre (am Bremskolben 2) Al pistón del cilindro principal HINWEIS: Die Feder auf der Seite mit dem klei- N.B.:...
Página 548 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake lever 1 Bolt (brake lever) 2 6 Nm (0.6 m · kg, 4.3 ft · lb) Nut (brake lever) 3 6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting...
Página 549 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO 2. Montieren: Monter: Instalar: Levier de frein 1 Bremshebel 1 Palanca del freno 1 Boulon (levier de frein) 2 Schraube (Bremshebel) 2 Perno (palanca del freno) 2 6 Nm (0,6 m ·...
Página 550 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Pin 1 Plain washer 2 Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” sec- tion in the CHAPTER 3. Front brake hose 1.
Página 551 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO 4. Montieren: Monter: Instalar: Goupille 1 Stift 1 Bulón 1 Rondelle ordinaire 2 Beilagscheibe 2 Arandela plana 2 Goupille fendue 3 Splint 3 Pasador hendido 3 HINWEIS:...
Página 552 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Copper washer 1 Brake hose 2 Union bolt 3 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that it contacts the master cylinder projection a and that its...
Página 553 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO 4. Montieren: Monter: Instalar: Rondelle en cuivre 1 Kupferscheibe 1 Arandela de cobre 1 Tuyau de frein 2 Bremsschlauch 2 Tubo del freno 2 Boulon-raccord 3 Hohlschraube 3...
Página 554 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake hose holder 1 Screw (brake hose holder) 2 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).
Página 555 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO 2. Montieren: Monter: Instalar: Support de tuyau de frein 1 Bremsschlauch-Halterung 1 Cubierta del tubo de frenos 1 Vis (support de tuyau de frein) Schraube (Halterung) 2 Tornillo (cubierta del tubo de frenos) 2...
Página 556 All manuals and user guides at all-guides.com CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: Brake system Refer “BRAKE SYSTEM BLEEDING” section in the CHAPTER 3. Inspect: Brake fluid level Fluid at lower level → Fill up. Refer “BRAKE FLUID LEVEL INSPECTION”...
Página 557 All manuals and user guides at all-guides.com FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO DELANTERO Y FRENO TRASERO 2. Entlüften: Purger l’air: Purgar el aire: Bremsanlage Système de freinage Sistema de frenos reporter à section Siehe unter “HYDRAULI- Consulte el apartado “PURGA “PURGE D’AIR DU SYS-...
Página 558: Front Fork
All manuals and user guides at all-guides.com CHAS FRONT FORK EC550000 FRONT FORK Extent of removal: 1 Front fork removal Extent of removal Order Part name Q’ty Remarks FRONT FORK REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Página 559: Fourche Avant
All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA FOURCHE AVANT Organisation de la dépose: 1 Dépose de la fourche avant Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA FOURCHE AVANT AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support...
Página 560 All manuals and user guides at all-guides.com CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY Extent of removal: 1 Oil seal removal 2 Damper rod removal Extent of removal Order Part name Q’ty Remarks FRONT FORK DISASSEMBLY Cap bolt Refer to “REMOVAL POINTS”. Fork spring Drain the fork oil.
Página 561: Demontage De La Fourche Avant
All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA DEMONTAGE DE LA FOURCHE AVANT 1 Dépose de la bague d’étanchéité 2 Dépose de la tige d’amortisseur Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté...
Página 562 All manuals and user guides at all-guides.com CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be main- tained at the dealers. CAUTION: To prevent an accidental explosion of air, following instructions should...
Página 563 N.B.: dere Aufmerksamkeit und sollte am La fourche avant nécessite une soi- ción especial. Por ello, recomendamos besten vom Yamaha-Händler gewar- gneuse attention. Il est donc recom- que el mantenimiento de la horquilla tet werden. mandé de la faire entretenir chez le delantera se realice en el concesionario.
Página 564: Ym-1423/90890-01423
All manuals and user guides at all-guides.com CHAS FRONT FORK EC553201 Inner tube 1. Remove: Dust seal 1 Stopper ring 2 Using slotted-head screwdriver. CAUTION: Take care not to scratch the inner tube. 2. Remove: Inner tube 1 Oil seal removal steps: Push in slowly a the inner tube just before it bottoms out and then pull it back quickly Repeat this step until the inner tube can...
Página 565: Poignée De Tige D'amortisseur
All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA Gleitrohr Tube interne Tubo interno 1. Demontieren: Déposer: Extraer: Joint antipoussière 1 Staubschutzring 1 Guardapolvos 1 Bague d’arrêt 2 Sicherungsring 2 Aro de tope 2 En utilisant un tournevis à lame Einen Schlitzschraubendre- destornillador droite.
Página 566 All manuals and user guides at all-guides.com CHAS FRONT FORK EC554200 Base valve 1. Inspect: Valve assembly 1 Wear/damage → Replace. O-ring 2 Damage → Replace. EC554400 Fork spring 1. Measure: Fork spring free length a Out of specification → Replace. Fork spring free length: Standard Limit...
Página 567 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA Luftventil Soupape de base Válvula base 1. Kontrollieren: Contrôler: Inspeccionar: Ensemble clapet 1 Luftventil 1 Conjunto de la válvula 1 Usure/endommagement → Verschleiß/Beschädigung → Desgaste/daños → Reempla- Changer.
Página 568: Assembly And Installation
All manuals and user guides at all-guides.com CHAS FRONT FORK EC554700 Cap bolt 1. Inspect: Cap bolt 1 O-ring 2 Air bleed screw 3 Wear/damage → Replace. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2.
Página 569 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA Verschlußschraube Bouchon de fourche Perno de la tapa 1. Kontrollieren: Contrôler: Inspeccionar: Boulon capuchon 1 Verschlußschraube 1 Perno de la tapa 1 Joint torique 2 O-Ring 2 Junta tórica 2 Vis de purge d’air 3 Entlüftungsschraube 3...
Página 570 All manuals and user guides at all-guides.com CHAS FRONT FORK 5. Install: Spring guide 1 Locknut 2 To damper rod 3. NOTE: Install the spring guide with its cut a facing upward. With its thread b facing upward, fully finger tighten the locknut onto the damper rod.
Página 571 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA 5. Montieren: Monter: Instalar: Guide de ressort 1 Federsitz 1 Guía del resorte 1 Contre-écrou 2 Sicherungsmutter 2 Contratuerca 2 Sur la tige d’amortisseur 3. (am Dämpferrohr 3) A la barra amortiguadora 3.
Página 572: Fork Seal Driver
All manuals and user guides at all-guides.com CHAS FRONT FORK 9. Install: Slide metal 1 Plain washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-01442/90890-01442 10.
Página 573: Outil D'insertion De Joint De Fourche
All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA 9. Montieren: Monter: Instalar: Bague antifriction 1 Gleitbuchse 1 Metal deslizante 1 Rondelle ordinaire 2 Beilagscheibe 2 Arandela plana 2 Dans l’ouverture tube (auf Gleitrohr-Nut) A la ranura del tubo externo. externe.
Página 574 All manuals and user guides at all-guides.com CHAS FRONT FORK 13. Check: Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: Front fork oil Until outer tube top surface with recom- mended fork oil 1.
Página 575 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA 13. Kontrollieren: 13. Contrôler: 13. Comprobar: Leichtgängigkeit des Stand- Mouvement régulier du tube Movimiento suave del tubo interne rohres interno Schwergängigkeit → Raideur/coincement/point dur Rigidez/ligadura/superficies → Répéter les étapes du 2 à 12. ásperas →...
Página 576 All manuals and user guides at all-guides.com CHAS FRONT FORK 19. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level.
Página 577 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA 19. Zehn Minuten warten, bis et- 19. Attendre dix minutes jusqu’à ce 19. Espere diez minutos hasta que se waige Luftbläschen sich auf- que les bulles d’air aient disparu hayan extraído las burbujas de de la fourche avant et que l’huile gelöst haben, bevor der Ga-...
Página 578 All manuals and user guides at all-guides.com CHAS FRONT FORK 21. Measure: Distance a Out of specification → Turn into the locknut. Distance a: 20 mm (0.79 in) or more Between damper rod 1 top and locknut 2 top. 22. Loosen: Rebound damping adjuster 1 NOTE: Loosen the rebound damping adjuster finger...
Página 579 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA 21. Messen: 21. Mesurer: 21. Medir: Distance a Gewindelänge a Distancia a Hors spécification → Serrer le Unvorschriftsmäßig → Die Fuera de especificaciones → contre-écrou. Sicherungsmutter hineindre- Girar la contratuerca.
Página 580 All manuals and user guides at all-guides.com CHAS FRONT FORK 26. Tighten: Cap bolt (locknut) 1 29 Nm (2.9 m · kg, 21 ft · lb) NOTE: While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4.
Página 581 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA 26. Festziehen: 26. Serrer: 26. Apretar: Verschlußschraube 1 Bouchon de fourche (contre- Perno de la tapa (contratuerca) écrou) 1 29 Nm (2,9 m · kg, 21 ft · lb) 29 Nm (2,9 m ·...
Página 582 All manuals and user guides at all-guides.com CHAS FRONT FORK 4. Tighten: Pinch bolt (handle crown) 1 23 Nm (2.3 m · kg, 17 ft · lb) Pinch bolt (under bracket) 2 20 Nm (2.0 m · kg, 14 ft · lb) CAUTION: Tighten the under bracket to specified torque.
Página 583 All manuals and user guides at all-guides.com FOURCHE AVANT TELESKOPGABEL CHAS HORQUILLA DELANTERA 4. Festziehen: Serrer: Apretar: Klemmschraube (obere Ga- Boulon de bridage (té de four- Perno de fijación (tija superior che supérieur) 1 belbrücke) 1 del manillar) 1 23 Nm (2,3 m · kg, 17 ft · lb) 23 Nm (2,3 m ·...
Página 584: Handlebar
All manuals and user guides at all-guides.com CHAS HANDLEBAR EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal Headlight Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side.
Página 585 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANILLAR GUIDON Organisation de la dépose: 1 Dépose du guidon Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU GUIDON Préparation pour la dépose Phare Câble de démarreur à chaud Déconnecter du côté...
Página 586 All manuals and user guides at all-guides.com CHAS HANDLEBAR EC5B3000 REMOVAL POINTS EC5B3100 Master cylinder 1. Remove: Master cylinder bracket 1 Master cylinder 2 CAUTION: Do not let the master cylinder hang on the brake hose. Keep the master cylinder cap side hori- zontal to prevent air from coming in.
Página 587 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANILLAR AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Hauptbremszylinder Maître-cylindre Cilindro principal Déposer: 1. Demontieren: Extraer: Demi-palier de fixation de maî- Hauptbremszylinder-Halte- Ménsula del cilindro principal tre-cylindre 1 rung 1 Maître-cylindre 2 Hauptbremszylinder 2 Cilindro principal 2...
Página 588: Assembly And Installation
All manuals and user guides at all-guides.com CHAS HANDLEBAR EC5B5000 ASSEMBLY AND INSTALLATION Handlebar 1. Install: Handlebar 1 Handlebar holder 2 Bolt (handlebar holder) 3 28 Nm (2.8 m · kg, 20 ft · lb) NOTE: The handlebar holder should be installed with the punched mark a forward.
Página 589 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANILLAR ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAJE E INSTALACIÓN Lenker Guidon Manillar Monter: 1. Montieren: Instalar: Guidon 1 Lenker 1 Manillar 1 Support de guidon 2 Lenkerhalterung 2 Soporte del manillar 2 Boulon (support de guidon) 3 Schraube (Lenkerhalterung) Perno (soporte del manillar) 3...
Página 590 All manuals and user guides at all-guides.com CHAS HANDLEBAR 4. Install: Cover (grip cap) 1 Throttle grip 2 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface. 5. Install: Throttle cables 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable wind-...
Página 591 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANILLAR 4. Montieren: Monter: Instalar: Abdeckung (Griffkappe) 1 Cache (capuchon de la poi- Cubierta (tapa de la empuña- gnée des gaz) 1 Gasdrehgriff 2 dura) 1 Poignée des gaz 2 Empuñadura del acelerador 2 HINWEIS: Lithium fett auf die Gasdrehgriff-...
Página 592 All manuals and user guides at all-guides.com CHAS HANDLEBAR 8. Install: Start switch 1 Master cylinder 2 Master cylinder bracket 3 Bolt (master cylinder bracket) 4 9 Nm (0.9 m · kg, 6.5 ft · lb) Clamp 5 NOTE: The start switch and master cylinder bracket should be installed according to the dimen- sions shown.
Página 593 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANILLAR 8. Montieren: Monter: Instalar: Commutateur de démarrage 1 Startschalter 1 Interruptor de arranque 1 Maître-cylindre 2 Hauptbremszylinder 2 Cilindro principal 2 Demi-palier de fixation de maî- Hauptbremszylinder-Halte- Ménsula del cilindro principal tre-cylindre 3 rung 3 Boulon (demi-palier de fixation...
Página 594 All manuals and user guides at all-guides.com CHAS HANDLEBAR 11. Adjust: Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. Hot starter lever free play Refer to “HOT STARTER LEVER ADJUSTMENT” section in the CHAP- TER 3. 12.
Página 595 All manuals and user guides at all-guides.com GUIDON LENKER CHAS MANILLAR 11. Einstellen: 11. Régler: 11. Ajustar: Kupplungszugspiel Jeu du levier d’embrayage Juego libre de la palanca del Se reporter à la section Siehe unter “KUPPLUNG embrague “REGLAGE DE EINSTELLEN” im KAPITEL 3. Consulte el apartado “AJUSTE L’EMBRAYAGE”...
Página 596: Steering
All manuals and user guides at all-guides.com CHAS STEERING EC560000 STEERING Extent of removal: 1 Under bracket removal 2 Bearing removal Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Página 597: Dirección
All manuals and user guides at all-guides.com DIRECTION LENKKOPF CHAS DIRECCIÓN DIRECTION Organisation de la dépose: 1 Dépose du té de fourche inférieur 2 Dépose du roulement Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA DIRECTION AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support...
Página 598 All manuals and user guides at all-guides.com CHAS STEERING Extent of removal Order Part name Q’ty Remarks Bearing (upper) Bearing (lower) Refer to “REMOVAL POINTS”. Ball race 5 - 47...
Página 599 All manuals and user guides at all-guides.com DIRECTION LENKKOPF CHAS DIRECCIÓN Organisation de la dépose Ordre Nom de pièce Qté Remarques Roulement (supérieur) Roulement (inférieur) Se reporter à “POINTS DE DEPOSE”. Cage à billes ETAPES DE SERRAGE: Serrer l’écrou annulaire à un couple d’environ. 38 Nm (3,8 m · kg, 27 ft · lb) Le desserrer d’un tour.
Página 600 All manuals and user guides at all-guides.com CHAS STEERING EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: Ring nut 1 Use the ring nut wrench 2. Ring nut wrench: YU-33975/90890-01403 WARNING Support the steering shaft so that it may not fall down. EC563300 Bearing (lower) 1.
Página 601 All manuals and user guides at all-guides.com DIRECTION LENKKOPF CHAS DIRECCIÓN AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Ringmutter Ecrou annulaire Tuerca anular Déposer: 1. Demontieren: Extraer: Ecrou annulaire 1 Ringmutter 1 Tuerca anular 1 Utiliser la clé pour écrou annu- Den Hakenschlüssel 2 ver- Utilice la llave dinamométrica laire 2.
Página 602: Assembly And Installation
All manuals and user guides at all-guides.com CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: Bearing 1 Ball race Pitting/damage → Replace bearings and ball races as a set. Install the bearing in the ball races.
Página 603 All manuals and user guides at all-guides.com DIRECTION LENKKOPF CHAS DIRECCIÓN Lager und Laufring Roulement et cage à billes Cojinete y guía de bolas 1. Die Lager und Laufringe in Lö- Nettoyer les roulements et les Lave los cojinetes y las guías de cages à...
Página 604 All manuals and user guides at all-guides.com CHAS STEERING 4. Install: Plain washer 1 Ring nut 2 7 Nm (0.7 m · kg, 5.1 ft · lb) Tighten the ring nut using the ring nut wrench 3. Refer to “STEERING HEAD INSPEC- TION AND ADJUSTMENT”...
Página 605 All manuals and user guides at all-guides.com DIRECTION LENKKOPF CHAS DIRECCIÓN 4. Montieren: Monter: Instalar: Rondelle ordinaire 1 Beilagscheibe 1 Arandela plana 1 Ecrou annulaire 2 Ringmutter 2 Tuerca anular 2 7 Nm (0,7 m · kg, 5,1 ft · lb) 7 Nm (0,7 m ·...
Página 606 All manuals and user guides at all-guides.com CHAS STEERING 9. Install: Steering shaft cap 1 10. After tightening the nut, check the steer- ing for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 11.
Página 607 All manuals and user guides at all-guides.com DIRECTION LENKKOPF CHAS DIRECCIÓN 9. Montieren: Monter: Instalar: Lenksäulenkappe 1 Tapa del eje de la dirección 1 Capuchon de colonne de direc- tion 1 10. Après avoir serré l’écrou, vérifier 10. Nach dem Festziehen der 10.
Página 608: Swingarm
All manuals and user guides at all-guides.com CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal Extent of removal Order Part name Q’ty Remarks SWINGARM REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Página 609: Bras Oscillant
All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS PALANCA OSCILANTE BRAS OSCILLANT Organisation de la dépose: 1 Dépose du bras oscillant Organisation de la dépose Ordre Nom de pièce Qté Remarques DÉPOSE DU BRAS OSCILLANT AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas de approprié...
Página 610 All manuals and user guides at all-guides.com CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY Extent of removal: 1 Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q’ty Remarks SWINGARM DISASSEMBLY Relay arm Connecting rod Collar...
Página 611: Desmontaje De La Palanca Oscilante
All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS PALANCA OSCILANTE DEMONTAGE DU BRAS OSCILLANT 1 Démontage du bras oscillant 2 Dépose et démontage de la bielle Organisation de la dépose: 3 Dépose et démontage du bras de relais Organisation de la dépose Ordre Nom de pièce...
Página 612 All manuals and user guides at all-guides.com CHAS SWINGARM EC573000 REMOVAL POINTS EC573200 Bearing 1. Remove: Bearing 1 NOTE: Install the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes, collars, and cov- ers in a solvent. EC574111 Swingarm 1.
Página 613 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS PALANCA OSCILANTE AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Lager Roulement Cojinete Déposer: 1. Demontieren: Extraer: Roulement 1 Lager 1 Cojinete 1 HINWEIS: N.B.: NOTA: Das Lager am äußeren Laufring her- Déposer le roulement en appuyant sur la Extraiga el cojinete empujando su pista auspressen.
Página 614 All manuals and user guides at all-guides.com CHAS SWINGARM EC574310 Connecting rod 1. Inspect: Bearing (polylube bearing) 1 Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: Bearing (polylube bearing) 1 Loss of solid lubrication → Replace. Oil seal 3 Damage →...
Página 615 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS PALANCA OSCILANTE Übertragungshebel Bielle Biela 1. Kontrollieren: Contrôler: Inspeccionar: Roulement (roulement poly- Lager (Polylube-Lager) 1 Cojinete (cojinete de polilube) lube) 1 Hülse 2 Collerette 2 Spiel/Schwergängigkeit/ Casquillo 2 Rost → Lager und Hülse im Jeu/rotation irrégulière/rouille Existe juego libre/vueltas brus- →...
Página 616 All manuals and user guides at all-guides.com CHAS SWINGARM 2. Install: Bearing 1 Oil seal 2 To relay arm. 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) 3.
Página 617 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS PALANCA OSCILANTE 2. Montieren: Monter: Instalar: Roulement 1 Lager 1 Cojinete 1 Bague d’étanchéité 2 Dichtring 2 Retén de aceite 2 Sur le bras relais. (am Umlenkhebel) Al brazo intermedio. HINWEIS: N.B.: NOTA:...
Página 618 All manuals and user guides at all-guides.com 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 Plain washer 3 Nut (connecting rod) 4 80 Nm (8.0 m ·...
Página 619 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS PALANCA OSCILANTE 3. Montieren: Monter: Instalar: Collerette 1 Hülse 1 Casquillo 1 Sur la bielle 2. (am Übertragungshebel 2) A la biela 2. HINWEIS: N.B.: NOTA: Molybdändisulfidfett auf Hülsen und Appliquer de la graisse au bisulfure de Aplique grasa de disulfuro de molibdeno den Dichringlippen auftragen.
Página 620 All manuals and user guides at all-guides.com CHAS SWINGARM 8. Install: Bolt (connecting rod) 1 Plain 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 Nut (rear shock absorber-relay arm) 2 53 Nm (5.3 m ·...
Página 621 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS PALANCA OSCILANTE 8. Montieren: Monter: Instalar: Boulon (bielle) 1 Schraube (Übertragungshe- Perno (biela) 1 Rondelle ordinaire 2 bel) 1 Arandela plana 2 Ecrou (bielle) 3 Beilagscheibe 2 Tuerca (biela) 3 Mutter (Übertragungshebel) N.B.: NOTA:...
Página 622 All manuals and user guides at all-guides.com CHAS SWINGARM 13. Install: Bolt [chain tensioner (lower)] 1 Plain washer 2 Collar 3 Chain tensioner 4 Nut [chain tensioner (lower)] 5 20 Nm (2.0 m · kg, 14 ft · lb) 14. Install: Chain support 1 Support cover 2 Bolt {chain support [r= 50 mm (1.97 in)]}...
Página 623 All manuals and user guides at all-guides.com BRAS OSCILLANT SCHWINGE CHAS PALANCA OSCILANTE 13. Montieren: 13. Monter: 13. Instalar: Schraube [Kettenspanner Boulon [tendeur de chaîne Perno [tensor de la cadena (inférieur)] 1 (unten)] 1 (inferior)] 1 Rondelle ordinaire 2 Beilagscheibe 2 Arandela plana 2 Collerette 3 Hülse 3...
Página 624: Rear Shock Absorber
All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER Extent of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal Order Part name Q’ty Remarks REAR SHOCK ABSORBER WARNING REMOVAL Support the machine securely so there is no Preparation for removal...
Página 625: Amortisseur Arriere
All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMORTIGUADOR TRASERO AMORTISSEUR ARRIERE Organisation de la dépose: 1 Dépose de l’amortisseur arrière 2 Démontage de l’amortisseur arrière Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE L’AMORTISSEUR AVERTISSEMENT ARRIERE Préparation pour la dépose...
Página 626 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q’ty Remarks Disconnect the starter relay cou- pler. Starter motor lead Disconnect at the starter relay side. Locking tie Taillight coupler Starting circuit cut-off relay cou- pler Plastic band Clamp (air filter joint)
Página 627 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMORTIGUADOR TRASERO Organisation de la dépose Ordre Nom de pièce Qté Remarques Débrancher le Raccord du relais de démarreur. Câble de démarreur Débrancher du côté du relais de démarreur. Attache Raccord de feu arrière Raccord du relais de coupe-circuit de démar-...
Página 628 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q’ty Remarks Spring (rear shock absorber) Bearing Refer to “REMOVAL POINTS”. 5 - 62...
Página 629 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMORTIGUADOR TRASERO Organisation de la dépose Ordre Nom de pièce Qté Remarques Ressort (amortisseur arrière) Roulement Se reporter à “POINTS DE DEPOSE”. Reihen- Demontage-Arbeiten Bauteil Anz. Bemerkungen folge Feder (Federbein) Lager Siehe unter “AUSBAU”.
Página 630 1. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. WARNING To dispose of a damaged or worn-out shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5 - 63...
Página 631 A la hora de desechar un amortigua- WARNUNG dor dañado o desgastado, lleve la uni- AVERTISSEMENT dad a su concesionario Yamaha. Den Stoßdämpfer vom Yamaha- Pour mettre au rebut un amortisseur Händler entsorgen lassen. endommagé ou usé, demander conseil à...
Página 632 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: Upper bearing 1 NOTE: Remove the bearing by pressing its outer race.
Página 633 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMORTIGUADOR TRASERO AUSBAU POINTS DE DEPOSE PUNTOS DE EXTRACCIÓN Lager Roulement Cojinete Déposer: 1. Demontieren: Extraer: Bague d’arrêt (Roulement Sicherungsring (Oberes La- Aro de tope (cojinete superior) supérieur) 1 ger) 1 HINWEIS: N.B.:...
Página 634 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585300 Bearing 1. Install: Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. CAUTION: Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear- ing is press fitted.
Página 635 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMORTIGUADOR TRASERO ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAJE E INSTALACIÓN Lager Roulement Cojinete Monter: 1. Montieren: Instalar: Roulement supérieur 1 Oberes Lager 1 Cojinete superior 1 HINWEIS: N.B.: NOTA: Das Lager am äußeren Laufring Monter le roulement parallèlement...
Página 636 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER 2. Tighten: Adjuster 1 3. Adjust: Spring length (installed) a Spring length (installed) a: Standard Extent of length adjustment 245 mm (9.65 in) 240.5 ~ 258.5 mm * 247 mm (9.72 in) (9.47 ~ 10.18 in) * For EUROPE, AUS, NZ and ZA NOTE:...
Página 637 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMORTIGUADOR TRASERO 2. Festziehen: Serrer: Apretar: Dispositif de réglage 1 Einstellmutter 1 Ajustador 1 Régler: 3. Einstellen: Ajustar: Longueur de ressort (monté) a Feder-Einbaulänge a Longitud del resorte (instalado) Longueur de ressort Feder-Einbaulänge a: (monté) a:...
Página 638 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER 2. Install: Bush 1 Collar 2 Dust seal 3 NOTE: Apply the molybdenum disulfide grease on the bearing. Apply the lithium soap base grease on the bush, collars and dust seals. Install the dust seals with their lips facing outward.
Página 639 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMORTIGUADOR TRASERO 2. Montieren: Monter: Instalar: Douille 1 Buchse 1 Buje 1 Collerette 2 Hülse 2 Casquillo 2 Joint antipoussière 3 Staubschutzring 3 Guardapolvos 3 HINWEIS: N.B.: NOTA: Molybdändisulfidfett auf das Lager Enduire le roulement de graisse au Aplique grasa de bisulfuro de molib- auftragen.
Página 640 All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER 8. Install: Plastic band 1 Starting circuit cut-off relay coupler 2 Taillight coupler 3 Locking tie 4 5 - 68...
Página 641 All manuals and user guides at all-guides.com AMORTISSEUR ARRIERE FEDERBEIN CHAS AMORTIGUADOR TRASERO 8. Montieren: Monter: Instalar: Bande en plastique 1 Plastikbinder 1 Banda plástica 1 Raccord du relais de coupe-cir- Starterkreis-Unterbrecherre- Acoplador del relé interruptor cuit de démarrage 2 laisstecker 2 del circuito de encendido 2 Raccord de feu arrière 3...
Página 642: Electrical Components And Wiring Diagram
All manuals and user guides at all-guides.com – ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 Headlight 0 Taillight COLOR CODE B/W....Black/White 2 “ENGINE STOP” A Neutral switch B.......Black L/B ....
Página 643 All manuals and user guides at all-guides.com COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE – ELEKTRISCHE BAUTEILE UND SCHALTPLAN ELEC COMPONENTES DEL SISTEMA ELÉCTRICO Y DIAGRAMA DE CABLES ELEKTRISCHE PARTIE SISTEMA ANLAGE ELECTRIQUE ELÉCTRICO COMPOSANTS ELECTRI- ELEKTRISCHE BAUTEI- COMPONENTES DEL SIS- LE UND SCHALTPLAN QUES ET SCHEMA DE TEMA ELÉCTRICO Y...
Página 644: Map-Controlled Cdi Unit
All manuals and user guides at all-guides.com – ELEC MAP-CONTROLLED CDI UNIT MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the WR450F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range.
Página 645 All manuals and user guides at all-guides.com – ELEC BLOC CDI CONTROLE PAR MICROPROCESSEUR BLOC CDI CONTROLE PAR MICROPROCESSEUR La WR450F est dotée d’un système d’allumage CDI contrôlé par microprocesseur. Le microprocesseur du bloc CDI détecte en permanence le régime du moteur ainsi que la position du papillon d’accélération, puis détermine l’avance à...
Página 646 All manuals and user guides at all-guides.com – ELEC KENNFELDGESTEUERTES CDI-ZÜNDSYSTEM KENNFELDGESTEUERTES CDI-ZÜNDSYSTEM Die WR450F ist mit einer kennfeldgesteuerten CDI-Zündanlage ausgestattet. Der Mikroprozessor in der CDI-Zündbox ist ständig über die Motordrehzahl und Drosselklappenpo- sition informiert und kann dadurch den optimalen Zündzeitpunkt im gesamten Lastbereich bestim- men.
Página 647 All manuals and user guides at all-guides.com – ELEC UNIDAD CDI CONTROLADA POR MAPA UNIDAD CDI CONTROLADA POR MAPA Para el modelo WR450F se utiliza un sistema de CDI encendido controlado por mapa. El microprocesador de la unidad CDI detecta la velocidad del motor y la posición del acelerador, lo que determina la óptima distribución de encendido a partir de su rango de funcionamiento completo.
Página 648: Ignition System
All manuals and user guides at all-guides.com – ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. No good Replace fuse and *1 Check fuse.
Página 649: Systeme D'allumage
All manuals and user guides at all-guides.com – ELEC SYSTEME D’ALLUMAGE SYSTEME D’ALLUMAGE ETAPES DU CONTROLE Suivre le procédé suivant pour déterminer si le mauvais fonctionnement du moteur est dû à une panne dans le circuit d’allumage et pour vérifier si une bougie ne produit pas d’étincelle. Mauvais Remplacer le fusible et *1 Vérifier le fusible.
Página 650: Taschen-Multimeter
All manuals and user guides at all-guides.com – ELEC ZÜNDANLAGE ZÜNDANLAGE FEHLERSUCHE Folgendes Diagramm hilft zündanlagen- und zündkerzenbedingte Motorstörungen zu beheben. Nicht in Ordnung Sicherung erneuern und *1 Sicherung prüfen. Kabelbaum prüfen. In Ordnung Nicht in Ordnung Neu aufladen oder *2 Batterie prüfen.
Página 651: Sistema De Encendido
All manuals and user guides at all-guides.com – ELEC SISTEMA DE ENCENDIDO SISTEMA DE ENCENDIDO PASOS PARA LA INSPECCIÓN Utilice los siguientes pasos para comprobar la posibilidad de un funcionamiento incorrecto del motor con res- pecto a un fallo del sistema de encendido o para comprobar que la bujía no enciende. Incorrecta Reemplace el fusible y *1 Compruebe el fusible.
Página 652 All manuals and user guides at all-guides.com – ELEC IGNITION SYSTEM SPARK GAP TEST Å 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (ignition checker 2) as shown. Ignition coil 3 Spark plug 4 Å...
Página 653 All manuals and user guides at all-guides.com SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC SISTEMA DE ENCENDIDO ZÜNDFUNKENSTRECKE KON- TEST DE L’INTERVALLE D’ETIN- PRUEBA DE LA SEPARACIÓN TROLLIEREN CELLEMENT D’ALLUMAGE ENTRE PUNTAS DE LA BUJÍA Débrancher la bobine d’allumage 1. Die Zündspule von der Zünd- Desconecte la bobina de encen- de la bougie.
Página 654 All manuals and user guides at all-guides.com – ELEC IGNITION SYSTEM MAIN SWITCH INSPECTION 1. Inspect: Main switch conduct Tester (+) lead → Red lead 1 Tester (–) lead → Brown lead 2 Tester selector position Ω × 1 Continuous while the main switch is moved to “OFF”...
Página 655 All manuals and user guides at all-guides.com SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC SISTEMA DE ENCENDIDO ZÜNDSCHALTER-INSPEKTION INSPECTION DU COUPE-CIR- INSPECCIÓN DEL INTERRUPTOR 1. Kontrollieren: CUIT DU MOTEUR PRINCIPAL Vérifier: Zündschalter-Leitungs- Inspeccionar: Conducteur du coupe-circuit du durchgang Conducto del interruptor prin- moteur cipal Meßkabel (+) →...
Página 656 All manuals and user guides at all-guides.com – ELEC IGNITION SYSTEM 3. Inspect: Secondary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Spark plug terminal 2 Secondary coil Tester selector resistance position 4.6 ~ 6.8 kΩ...
Página 657 All manuals and user guides at all-guides.com SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC SISTEMA DE ENCENDIDO 3. Kontrollieren: Vérifier: Inspeccione: Sekundärspulen-Wider- Résistance de bobine secon- Resistencia de la bobina secun- daire stand daria Hors spécification → Remplacer. Unvorschriftsmäßig → Fuera de especificaciones → Erneuern.
Página 658 All manuals and user guides at all-guides.com – ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON”, the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed).
Página 659: System De Demar- Rage Electrique
All manuals and user guides at all-guides.com SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM – ELEC SYSTEMA DE ARRANQUE ELÉCTRICO SYSTEM DEMAR- ELEKTROSTARTERSY- SYSTEMA DE ARRAN- STEM RAGE ELECTRIQUE QUE ELÉCTRICO FUNKTION DES STARTSYSTEMS FONCTIONNEMENT SYS- FUNCIONAMIENTO SIS- Wenn sich das Zündschloß in Stel- TEME DE COUPURE DU CIRCUIT TEMA DE INTERRUPCIÓN DEL lung “ON”...
Página 660 All manuals and user guides at all-guides.com – ELEC ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. No good Replace fuse and *1 Check fuse check wire harness. No good *2 Check battery Recharge or replace.
Página 661 All manuals and user guides at all-guides.com – ELEC SYSTEM DE DEMARRAGE ELECTRIQUE POINTS A CONTROLER Si le moteur de démarreur ne fonctionne pas, effectuer les contrôles suivants. Mauvais Remplacer le fusible et *1 Contrôler le fusible. vérifier le faisceau de fils. O.K.
Página 662 All manuals and user guides at all-guides.com – ELEC ELEKTROSTARTERSYSTEM INSPEKTIONSSCHRITTE Wenn der Startermotor nicht arbeitet, mit den folgenden Schritten überprüfen. Nicht in Ordnung Sicherung erneuern und *1 Sicherung prüfen. Kabelbaum prüfen. In Ordnung Nicht in Ordnung Neu aufladen oder *2 Batterie prüfen.
Página 663: Pasos De Inspección
All manuals and user guides at all-guides.com – ELEC SYSTEMA DE ARRANQUE ELÉCTRICO PASOS DE INSPECCIÓN Si el motor de arranque no funciona, realice los pasos siguientes de inspección. Incorrecta Reemplace el fusible y *1 Compruebe el fusible. compruebe el cableado. Incorrecta *2 Compruebe la batería.
Página 664 All manuals and user guides at all-guides.com – ELEC ELECTRIC STARTING SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. STARTER MOTOR OPERATION 1. Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3.
Página 665 All manuals and user guides at all-guides.com SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM – ELEC SYSTEMA DE ARRANQUE ELÉCTRICO KONTROLLE LEITUNGS- INSPECTION DE LA CONNEXION INSPECCIÓN DE LA CONEXIÓN STECKERN UND LEITUNGSVER- DES RACCORDS ET DES FILS ACOPLADORES Contrôler: BINDUNGEN CABLES Connexion des raccords et des 1.
Página 666: Electric Starting System
All manuals and user guides at all-guides.com – ELEC ELECTRIC STARTING SYSTEM STARTER RELAY INSPECTION 1. Remove: Starter relay 2. Inspect: Starter relay conduct Use 12 V battery. Battery (+) lead → Starter relay terminal 1 Battery (–) lead → Starter relay terminal 2 Tester (+) lead →...
Página 667 All manuals and user guides at all-guides.com SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM – ELEC SYSTEMA DE ARRANQUE ELÉCTRICO STARTER-RELAIS-KONTROLLE INSPECTION RELAIS INSPECCIÓN RELÉ 1. Demontieren: DEMARREUR ARRANCADOR Déposer: Starterrelais Desmontar: Relais de démarreur 2. Kontrollieren: Relé del arrancador Inspecter: Starterrelais-Durchgang Inspeccionar: Conducteur de relais de démar- 12-V-Batterie verwenden.
Página 668 All manuals and user guides at all-guides.com – ELEC ELECTRIC STARTING SYSTEM DIODE INSPECTION 1. Remove the diode from wire harness. 2. Inspect: Diode continuity Use pocket tester (tester selection posi- tion Ω × 1) Tester (+) → Blue/Red terminal 1 Continuous Tester (–) →...
Página 669 All manuals and user guides at all-guides.com SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM – ELEC SYSTEMA DE ARRANQUE ELÉCTRICO DIODEN-INSPECTION INSPECTION DE LA DIODE INSPECCIÓN DEL DIODO 1. Die Diode vom Kabelbaum Déposer la diode du faisceau de Quite el diodo del cableado. fils.
Página 670: Starter Motor
All manuals and user guides at all-guides.com – ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR Extent of removal: 1 Starter motor disassembly Extent of removal Order Part name Q’ty Remarks STARTER MOTOR REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3.
Página 671: Motor De Arranque
All manuals and user guides at all-guides.com SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM – ELEC SYSTEMA DE ARRANQUE ELÉCTRICO MOTEUR DE DÉMARREUR Organisation de la dépose: Démontage du moteur dé demarreur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU MOTEUR DE DEMARREUR Préparation à...
Página 672 All manuals and user guides at all-guides.com – ELEC ELECTRIC STARTING SYSTEM Extent of removal Order Part name Q’ty Remarks Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring 6 - 13...
Página 673 All manuals and user guides at all-guides.com SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM – ELEC SYSTEMA DE ARRANQUE ELÉCTRICO Organisation de la dépose Ordre Nom de pièce Qté Remarques Stator de démarreur Ensemble de l’armature Couvercle arrière de démarreur Balais Ressort de balais Reihen- Demontage-Arbeiten Bauteil...
Página 674 All manuals and user guides at all-guides.com – ELEC ELECTRIC STARTING SYSTEM INSPECTION AND REPAIR 1. Check: Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: Commutator diameter a Out of specification → Replace the starter motor. Min. commutator diameter 16.6 mm (0.65 in) 3.
Página 675 All manuals and user guides at all-guides.com SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM – ELEC SYSTEMA DE ARRANQUE ELÉCTRICO KONTROLLE UND REPARATUR INSPECTION ET REPARATION INSPECCIÓN Y REPARACIÓN 1. Kontrollieren: Inspecter: Comprobar: Commutateur Kommutator Conmutador Sale → Nettoyer avec du Schmutz → Mit Sandpapier Suciedad →...
Página 676 All manuals and user guides at all-guides.com – ELEC ELECTRIC STARTING SYSTEM 5. Measure: Brush length a Out of specification → Replace the brushes as a set. Min. brush length 3.5 mm (0.14 in) 6. Measure: Brush spring force Out of specification → Replace the brush springs as a set.
Página 677 All manuals and user guides at all-guides.com SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM – ELEC SYSTEMA DE ARRANQUE ELÉCTRICO 5. Messen: Mesurer: Medir: Longueur des balais a Bürstenlänge a Longitud de la escobilla a Hors spécification → Rempla- Unvorschriftsmäßig → Die Fuera de especificación →...
Página 678 All manuals and user guides at all-guides.com – ELEC ELECTRIC STARTING SYSTEM 3. Install: O-ring 1 Starter motor yoke 2 NOTE: Align the match mark on the starter motor yoke with the match mark b on the starter motor rear cover. Install the starter motor yoke with its groove c facing rear cover.
Página 679 All manuals and user guides at all-guides.com SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM – ELEC SYSTEMA DE ARRANQUE ELÉCTRICO 3. Montieren: Installer : Instalar: Joint torique 1 O-Ring 1 Junta tórica 1 Stator de démarreur 2 Startermotorjoch 2 Carcasa del motor de arranque HINWEIS: N.B.: Faire coïncider le repère a sur le sta-...
Página 680: Charging System
All manuals and user guides at all-guides.com – ELEC CHARGING SYSTEM EC680000 CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. No good Replace fuse and *1 Check fuse. check wire harness. No good *2 Check battery.
Página 681: Systeme De Recharge
All manuals and user guides at all-guides.com – ELEC SYSTEME DE RECHARGE SYSTEME DE RECHARGE ETAPES DU CONTROLE Si la batterie ne se recharge pas, effectuer les contrôles suivants. Remplacer le fusible et Mauvais *1 Vérifier le fusible. contrôler le faisceau de fils.
Página 682 All manuals and user guides at all-guides.com – ELEC LADESYSTEM LADESYSTEM FEHLERSUCHE Wenn die Batterie nicht geladen wird, mit den folgenden Schritten überprüfen. Nicht in Ordnung Sicherung erneuern und *1 Sicherung prüfen. Kabelbaum prüfen. In Ordnung Nicht in Ordnung Neu aufladen oder *2 Batterie prüfen.
Página 683: Sistema De Carga
All manuals and user guides at all-guides.com – ELEC SISTEMA DE CARGA SISTEMA DE CARGA PASOS DE INSPECCIÓN Si la batería no se carga, realice los pasos siguientes de inspección. Incorrecta Reemplace el fusible y *1 Compruebe el fusible. compruebe el cableado. Incorrecta *2 Compruebe la batería.
Página 684 All manuals and user guides at all-guides.com – ELEC CHARGING SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHARGING VOLTAGE INSPECTION 1. Start the engine. 2. Inspect: Charging voltage Out of specification → If no failure is found in checking the source coil resis- tance, replace the rectifier/regulator.
Página 685 All manuals and user guides at all-guides.com SYSTEME DE RECHARGE LADESYSTEM – ELEC SISTEMA DE CARGA KONTROLLE LEITUNGS- INSPECTION DE LA CONNEXION INSPECCIÓN DE LA CONEXIÓN STECKERN UND LEITUNGSVER- DES RACCORDS ET DES FILS ACOPLADORES Contrôler: BINDUNGEN CABLES Connexion des raccords et des 1.
Página 686 All manuals and user guides at all-guides.com – ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM EC690000 TPS (THROTTLE POSITION SENSOR) SYSTEM INSPECTION STEPS If the TPS will not operate, use the following inspection steps. No good Check entire ignition Repair or replace. system for connection.
Página 687 All manuals and user guides at all-guides.com SYSTEME TPS – ELEC (CAPTEUR DU PAPILLON D’ACCELERATION) SYSTEME TPS (CAPTEUR DU PAPILLON D’ACCELERATION) ETAPES DU CONTROLE Si le TPS ne fonctionne pas, effectuer les contrôles suivants. Vérifier la connexion de tout le Mauvais Réparer ou remplacer.
Página 688 All manuals and user guides at all-guides.com TPS-SYSTEM – ELEC (DROSSELKLAPPEN-POSITIONSSENSOR) TPS-SYSTEM (DROSSELKLAPPEN-POSITIONSSENSOR) INSPEKTIONSSCHRITTE Den TPS bei einem Ausfall wie folgt überprüfen. Nicht in Ordnung Die gesamte Zündanlage Erneuern oder instand auf Anschluß überprüfen. setzen. In Ordnung Nicht in Ordnung Den TPS prüfen.
Página 689: Sistema Tps (Sensor De Posición Del Acelerador)
All manuals and user guides at all-guides.com SISTEMA TPS – ELEC (SENSOR DE POSICIÓN DEL ACELERADOR) SISTEMA TPS (SENSOR DE POSICIÓN DEL ACELERADOR) PASOS DE INSPECCIÓN Si el TPS no funciona, utilice los siguientes pasos de inspección. Compruebe la conexión de Incorrecto Reparar o reemplazar.
Página 690 All manuals and user guides at all-guides.com – ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM HANDLING NOTE CAUTION: Do not loosen the screws {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance.
Página 691 All manuals and user guides at all-guides.com SYSTEME TPS (CAPTEUR DU PAPILLON D’ACCELERATION) – TPS-SYSTEM (DROSSELKLAPPEN-POSITIONSSENSOR) ELEC SISTEMA TPS (SENSOR DE POSICIÓN DEL ACELERADOR) HINWEIS ZUM UMGANG REMARQUE NOTA SOBRE EL MANEJO ACHTUNG: ATTENTION: ATENCION: Ne pas desserrer la vis (TPS) 1 sauf Nicht die Schraube (Drosselpositi- No aflojar el tornillo {TPS (sensor de s’il faut changer le capteur de position...
Página 692 All manuals and user guides at all-guides.com – ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 3. Inspect: TPS coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open posi- tion.
Página 693 All manuals and user guides at all-guides.com SYSTEME TPS (CAPTEUR DU PAPILLON D’ACCELERATION) – TPS-SYSTEM (DROSSELKLAPPEN-POSITIONSSENSOR) ELEC SISTEMA TPS (SENSOR DE POSICIÓN DEL ACELERADOR) 3. Prüfen: Contrôler: Inspeccionar: Regelwiderstand der TPS- Résistance variable Resistencia variable de la bobine de TPS Spule bobina TPS S’assurer que la résistance aug-...
Página 694 All manuals and user guides at all-guides.com – ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 4. Adjust: Idle speed Refer to “IDLE SPEED ADJUST- MENT” section in the CHAPTER 3. 5. Insert the thin electric conductors 2 (lead) into the TPS coupler 1, as shown, and connect the tester to them.
Página 695 All manuals and user guides at all-guides.com SYSTEME TPS (CAPTEUR DU PAPILLON D’ACCELERATION) – TPS-SYSTEM (DROSSELKLAPPEN-POSITIONSSENSOR) ELEC SISTEMA TPS (SENSOR DE POSICIÓN DEL ACELERADOR) 4. Einstellen: Régler: Ajustar: Leerlaufdrehzahl Vitesse de ralenti Velocidad de ralentí Voir “Réglage du ralenti” au Siehe hierzu den Abschnitt Consultar apartado...
Página 696: Tps (Throttle Position Sensor) System
All manuals and user guides at all-guides.com – ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 8. Tighten: Screw (TPS) 1 9. Stop the engine. EC694000 TPS INPUT VOLTAGE INSPECTION 1. Disconnect the TPS coupler. 2. Start the engine. 3. Inspect: TPS input voltage Out of specification →...
Página 697: Inspección De La Tensión De Entrada Del Tps
All manuals and user guides at all-guides.com SYSTEME TPS (CAPTEUR DU PAPILLON D’ACCELERATION) – TPS-SYSTEM (DROSSELKLAPPEN-POSITIONSSENSOR) ELEC SISTEMA TPS (SENSOR DE POSICIÓN DEL ACELERADOR) 8. Festziehen: Serrer: Apretar: Vis (TPS) 1 Schraube (TPS) 1 Tornillo (TPS) 1 Arrêter le moteur 9.
Página 698: Lighting System
All manuals and user guides at all-guides.com – ELEC LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible problems. Check the bulb and bulb Replace the bulb and/ No good socket.
Página 699: Systeme D'eclairage
All manuals and user guides at all-guides.com – ELEC SYSTEME D’ECLAIRAGE SYSTEME D’ECLAIRAGE PROCEDURES DE VERIFICATION Se référer au tableau suivant lors de l’inspection du système d’allumage lors de pannes. Mauvais Contrôler l’ampoule et le culot Remplacer l’ampoule et/ou d’ampoule. le culot d’ampoule.
Página 700 All manuals and user guides at all-guides.com – ELEC LICHTANLAGE LICHTANLAGE KONTROLLSCHRITTE Bei der Überprüfung der Zündanlage auf mögliche Störungen ist das folgende Ablaufdiagramm zu beachten. Nicht in Ordnung Lampe und Lampenstecker Lampe und/oder Lam- überprüfen. penstecker erneuern. In Ordnung Nicht in Ordnung Lichtmaschi- AC Magnetzürder überprüfen.
Página 701: Sistema De Alumbrado
All manuals and user guides at all-guides.com – ELEC SISTEMA DE ALUMBRADO SISTEMA DE ALUMBRADO PASOS PARA LA INSPECCIÓN Consulte la siguiente tabla cuando inspeccione el sistema de encendido para cualquier posible problema. Incorrecta Compruebe la bombilla y Reemplace la bombilla y/o el portabombillas.
Página 702 All manuals and user guides at all-guides.com – ELEC LIGHTING SYSTEM AC MAGNETO INSPECTION 1. Inspect: Lighting coil resistance Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Ground 2 Lighting coil Tester selector resistance position 0.224 ~ 0.336 Ω...
Página 703 All manuals and user guides at all-guides.com SYSTEME D’ECLAIRAGE LICHTANLAGE – ELEC SISTEMA DE ALUMBRADO AC MAGNETZÜNDER KONTROL- VERIFICATION DE LA MAGNETO INSPECCIÓN DEL MAGNETO DE LIEREN Inspection: 1. Kontrollieren: Inspeccione: Widerstand Lichtma- Résistance de la bobine d’allu- Resistencia de la bobina de schinenwicklung mage alumbrado...
Página 704 All manuals and user guides at all-guides.com T U N SETTING EC700000 TUNING EC710000 ENGINE Carburetor setting The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is nec- essary to take into consideration the air pres- sure, ambient temperature, humidity, etc., when adjusting the carburetor.
Página 705: Puesta A Punto
All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE ABSTIMMUNG MISES AU POINT PUESTA A PUNTO MOTOR MOTEUR MOTOR Vergaser einstellen Réglage de carburateur Ajuste del carburador Das Luft/Kraftstoffgemisch variiert La qualité de l’émulsion air/essence La mezcla de aire/combustible variará mit den atmosphärischen Bedin- dépend des conditions atmosphéri- dependiendo...
Página 706 All manuals and user guides at all-guides.com T U N SETTING CAUTION: The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. Always handle the carburetor and its components carefully.
Página 707 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE ACHTUNG: ATTENTION: ATENCION: Le carburateur est extrêmement Der Vergaser ist extrem emp- El carburador es extremadamente sensible à toute pénétration de cras- findlich gegen Fremdkörper sensible a los materiales extraños ses, sable, eau, etc.
Página 708 All manuals and user guides at all-guides.com T U N SETTING Effects of the setting parts on the throttle valve opening Å Closed ı Fully open Å ı 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.
Página 709 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Wirkung der Einstellteile in Bezug Effets des réglages sur l’ouverture du Efectos de las piezas de ajuste en la auf die Öffnung der Drosselklappe boisseau abertura de la válvula del acelerador Å...
Página 710 All manuals and user guides at all-guides.com T U N SETTING Pilot system The FLATCR carburetor is manufactured with a pilot screw. The pilot screw adjustment ranges from fully closed throttle to 1/4 open throttle. Main jet adjustment The richness of the air-fuel mixture at full throt- tle can be set by changing the main jet 1.
Página 711 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Leerlaufsystem Circuit de ralenti Sistema piloto Der FLATCR-Vergaser verfügt über Le circuit de ralenti est équipé d’une vis El carburador FLATCR está fabricado de ralenti. La plage de réglage de la vis eine Leerlauf-Regulierschraube.
Página 712 All manuals and user guides at all-guides.com T U N SETTING Pilot screw adjustment The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1. Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it.
Página 713 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Einstellung der Leerlaufgemisch- Réglage de la vis de ralenti Ajuste del tornillo piloto Regulierschraube La richesse de l’émulsion air-essence à Se puede ajustar la riqueza de la mezcla une ouverture des gaz de 0 à...
Página 714 All manuals and user guides at all-guides.com T U N SETTING Pilot jet adjustment The richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjust- ing the pilot jet 1. Standard pilot jet * #48 * Except for USA Effects of adjusting the pilot jet (reference)
Página 715 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Leerlaufdüse einstellen Réglage du gicleur de ralenti Ajuste del surtidor piloto Le gicleur de ralenti 1 permet de régler Der Kraftstoffgehalt des Luft-Kraft- Se puede ajustar la riqueza de la mezcla la richesse de l’émulsion air-essence à...
Página 716 All manuals and user guides at all-guides.com T U N SETTING Jet needle adjustment The jet needle is adjusted by changing it. OBDWR Standard jet needle * OBDUQ * 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.
Página 717 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Düsennadel einstellen Réglage de l’aiguille Ajuste de la aguja del surtidor Die Düsennadel wird eingestellt, L’aiguille se règle en la changeant. La aguja del surtidor se ajusta cambián- indem sie ausgetauscht wird.
Página 718 All manuals and user guides at all-guides.com T U N SETTING Carburetor setting parts Part name Size Part number Main jet Rich #175 4MX-14943-42 #172 4MX-14943-92 #170 4MX-14943-41 #168 4MX-14943-91 (STD) #165 4MX-14943-40 #162 4MX-14943-90 *(STD) #160 4MX-14943-39 #158 4MX-14943-89 #155 4MX-14943-38 #152...
Página 719 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Vergaser-Einstellteile Pièces modifiables du carburateur Piezas de ajuste del carburador Numéro de Grö- Nombre de la Tama- Número de la Nom de pièce Taille Bauteil Teilenummer pièce ße pieza ño...
Página 720 All manuals and user guides at all-guides.com T U N SETTING Examples of carburetor setting depending on symptom Symptom Setting Checking Discoloration of spark plug → At full throttle Increase main jet calibration no. Hard breathing (Gradually) If tan color, it is in good condition. Shearing noise If cannot be corrected: Whitish spark plug...
Página 721 All manuals and user guides at all-guides.com T U N REGLAGE Exemples de réglages de carburateur en fonction des symptômes Symptômes Réglages Contrôles Décoloration de bougie → A pleine ouverture des gaz Monter un gicleur principal de n˚ de cali- Crachotements bre supérieur.
Página 722 All manuals and user guides at all-guides.com T U N EINSTELLUNG Beispiele für die Vergasereinstellung in bezug auf bestimmte Symptome Symptom Einstellung Prüfung Verfärbung der Zündkerze → Bei Vollgas Hauptdüsen-Nr. erhöhen (schrittweise) “Schweres Atmen” Rehbraune Färbung weist auf guten Abschergeräusch Zustand hin.
Página 723 All manuals and user guides at all-guides.com T U N AJUSTE Ejemplo de ajuste del carburador dependiendo del síntoma Síntoma Ajuste Comprobación → Con el acelerador al máximo Aumente el n˚ de calibración del surtidor Decoloración de la bujía La respiración es dificultosa principal.
Página 724 All manuals and user guides at all-guides.com T U N 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 <Requirement for selection of secondary gear reduction ratio>...
Página 725 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE PARTIE CYCLE FAHRGESTELL CHASIS Sekundärüntersetzungsverhältnis Sélection du taux de réduction secon- Selección de la relación de la reduc- (Kettenräder) wählen daire (Pignons) ción secundaria (Piñón) Nombre de dents Número de dien- Anzahl der Zähne du pignon mené...
Página 726 All manuals and user guides at all-guides.com T U N SETTING EC72N000 Drive and driven sprockets setting parts Part name Size Part number Drive sprocket 1 (STD) 5NG-17460-00 *(STD) *14T 9383E-14215 **15T 9383E-15082 * For CDN, EUROPE, AUS, NZ and ZA ** For AUS and NZ Part name Size...
Página 727 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Antriebsritzel und Kettenräder Pièces de réglage des pignons mené et Piezas de ajuste de los piñones de menant accionamiento e impulsión Teilenum- Bauteil Größe Numéro Nombre de la Número de la Nom de pièce Taille de pièce...
Página 728 All manuals and user guides at all-guides.com T U N SETTING EC722011 Front fork setting The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1.
Página 729 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Teleskopgabel einstellen Réglages de la fourche avant Ajuste de la horquilla delantera Die Einstellung der Gabel sollte ent- Régler la fourche avant en fonction de la El ajuste de la horquilla delantera debe realizarse dependiendo de la sensación sensation lors de la conduite ainsi que sprechend dem Gefühl des Fahrers,...
Página 730 All manuals and user guides at all-guides.com T U N SETTING EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. CAUTION: Do not install three or more adjustment washers for each front fork.
Página 731 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Federvorspannung einstellen Réglage de tension initiale du ressort Ajuste de la precarga del resorte Die Federvorspannung wird durch Le tension initiale du ressort a été ajustée La precarga del resorte se ajusta insta- en montant la rondelle de réglage 1 den Einbau einer Einstellscheibe 1 lando la arandela de ajuste 1 entre el...
Página 732 All manuals and user guides at all-guides.com T U N SETTING 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar.
Página 733 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE 2. Harte Feder Ressort dur Utilice un resorte rígido Eine harte Feder bewirkt prin- En principe, un ressort dur offre Normalmente, un resorte rígido une sensation de conduite dure. zipiell ein hartes Fahrgefühl.
Página 734: Part Number
All manuals and user guides at all-guides.com T U N SETTING EC72P000 Front fork setting parts Adjustment washer 1 TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 4SS-23364-L0 Front fork spring 2 [Equal pitch spring] I.D. SPRING SPRING TYPE MARK RATE...
Página 735 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Vorderradgabel-Einstellteile Pièces de réglage de la fourche avant Piezas de ajuste de la horquilla delan- Rondelle de réglage 1 Einstellscheibe 1 tera Arandela de ajuste 1 TYPE NUMÉRO DE TEILENUM- TYP (Dicke)
Página 736 All manuals and user guides at all-guides.com T U N SETTING EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the fol- lowing two factors: 1.
Página 737 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Hinterradaufhängung einstellen Réglage de la suspension arrière Ajuste de la suspensión trasera Die Einstellung der Hinterradaufhän- Effectuer le réglage de la suspension El ajuste de la suspensión trasera debe arrière en fonction de la sensation lors de gung soll entsprechend dem Gefühl realizarse dependiendo de la sensación...
Página 738 All manuals and user guides at all-guides.com T U N SETTING NOTE: If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re- evaluation.
Página 739 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE HINWEIS: N.B.: NOTA: Le ressort peut s’allonger au fur et à Die Federeinbaulänge kann sich Si el vehículo es nuevo y se ha efec- mesure de la période de rodage. Il est beim Einfahren verändern, u.a.
Página 740 All manuals and user guides at all-guides.com T U N SETTING CAUTION: When using a rear cushion other than cur- rently installed, use the one whose overall length a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard.
Página 741 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE ACHTUNG: ATTENTION: ATENCION: Lors du remplacement du ressort de Beim Austausch des Federbeins Cuando utilice un amortiguador tra- la suspension arrière, veiller à monter darauf achten, daß die Gesamtlän- sero distinto al instalado, debe utilizar un ressort dont la longueur totale a ge a das Standardmaß...
Página 742 All manuals and user guides at all-guides.com T U N SETTING EC72Q000 Rear shock absorber setting parts Rear shock spring 1 [Equal pitch spring] I.D. SPRING SPRING SPRING TYPE COLOR/ FREE RATE PART NUMBER POINT LENGTH 5UN-22212-00 Brown/1 SOFT 5UN-22212-10 Green/1 5UN-22212-20 Red/1...
Página 743 All manuals and user guides at all-guides.com REGLAGE EINSTELLUNG T U N AJUSTE Hinterradstoßdämpfer-Einstell- Pièces de réglage de l’amortisseur Piezas de ajuste del amortiguador tra- teile arrière sero Ressort d’amortisseur arrière 1 Hinterradstoßämpfer-Schrauben- Resorte del amortiguador trasero 1 [Ressort à pas égal] feder 1 [Resorte de paso regular] [Feder mit gleichmäßiger Gewinde-...
Página 744 All manuals and user guides at all-guides.com T U N SETTING EC72H002 Suspension setting Front fork NOTE: If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.9 in).
Página 745 All manuals and user guides at all-guides.com T U N SETTING Rear shock absorber NOTE: If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. Adjust the rebound damping in 2-click increments or decrements.
Página 746 All manuals and user guides at all-guides.com T U N REGLAGE Réglage de la suspension Fourche avant N.B.: Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectuer un nouveau réglage en se référant aux procédés repris dans ce tableau. Avant d’effectuer toute modification, régler la longueur enfoncée de l’amortisseur arrière comprimé...
Página 747 All manuals and user guides at all-guides.com T U N REGLAGE Amortisseur arrière N.B.: Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectuer un nouveau réglage en se référant aux procédés repris dans ce tableau. Régler la force de rebondissement de 2 clics dans un sens ou l’autre.
Página 748 All manuals and user guides at all-guides.com T U N EINSTELLUNG Fahrwerksabstimmung Teleskopgabel HINWEIS: Liegen bei Normaleinstellung folgende Symptome vor, wie folgt vorgehen. Vor der Einstellung der Gabel das Federbein auf die Standard-Federeinbaulänge von 90–100 mm (3,5–3,9 in) einstellen. Strecke Große Mittlere Kleine...
Página 749 All manuals and user guides at all-guides.com T U N EINSTELLUNG Federbein HINWEIS: Liegen bei Normaleinstellung folgende Symptome vor, wie folgt vorgehen. Die Zugstufendämpfung jeweils um 2 Rasterstufen stärker oder schwächer verstellen. Die Tiefdruckdämpfung jeweils um 1 Rasterstufe stärker oder schwächer verstellen. Die Hochdruckdämpfung jeweils um eine 1/6-Drehung stärker oder schwächer verstellen.
Página 750 All manuals and user guides at all-guides.com T U N AJUSTE Ajuste de la suspensión Horquilla delantera NOTA: Si aparece cualquiera de los siguientes síntomas con la posición estándar de base, realice los ajustes nueva- mente consultando el procedimiento de ajuste descrito en la misma tabla. Antes de efectuar ningún cambio, ajuste la longitud de hundimiento del amortiguador trasero en 90 ~ 100 mm (3,5 ~ 3,9 in).
Página 751 All manuals and user guides at all-guides.com T U N AJUSTE Amortiguador trasero NOTA: Si aparece cualquiera de los siguientes síntomas con la posición estándar de base, realice los ajustes nueva- mente consultando el procedimiento de ajuste descrito en la misma tabla. Ajuste el retorno del amortiguador en incrementos y disminuciones de 2 clics.
Página 752 All manuals and user guides at all-guides.com...
Página 753 All manuals and user guides at all-guides.com...
Página 754 All manuals and user guides at all-guides.com YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.08-2.4×1 CR 2500 SHINGAI IWATA SHIZUOKA JAPAN (E,F,G,S)

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