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2001 yamaha yz125 service manual free download |
2001 yamaha yz125 service manual free download
Yamaha Service & Repair Manuals. DTC - Free Download PDF -
Table Of Contents. Quick Links. Table of Contents. Previous Page. Next Page. Yamaha yz 1cc38 motorcycles parts catalog 60 pages. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co. Printed in Japan It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. Dieses Modell entspricht fort It is illegal for this machine to be op- erated on any public street, road, or highway. Off-road use on public lands may also be illegal.
Please check local regulations before riding. Page 8 5. Always turn off the engine while refuel- ing. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, Page 9 5.
Dar- Spegnere sempre il motore faisant le plein. Page 10 Some data in this manual may become out- dated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer.
EC F. Les poids minimum admis pour les Failure to follow WARNING instructions could re- sult in severe injury or death to the machine op- erator, a bystander, or a person inspecting or re- pairing the machine.
The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e. Page Machine Identification There are two significant reasons for knowing the serial number of your machine: 1.
When ordering parts, you can give the num- ber to your Yamaha dealer for positive iden- tification of the model you own. If your machine is stolen, the authorities will need the number to search for and identify your machine. Remove all dirt, mud, dust, and foreign ma- terial before removal and disassembly. When washing the machine with high pres- sured water, cover the parts as follows. Eliminer soigneusement crasse, 1. We recommend to use Yamaha genuine parts for all replacements. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled.
Page 33 Yamaha per tutti i ricambi. Bauteile zu verwenden. All circlips should be inspected carefully be- fore reassembly. Always replace piston pin clips after one use. Replace distorted cir- clips.
When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite to the thrust 3 it receives. Avant remontage, tous les circlips 1. Alle Sicherungsringe vor dem Wie- 1. Disconnect: 9Connector 2.
Dry each terminal with an air blower. Connect and disconnect the connector two or three times. Pull the lead to check that it will not come off. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and part number used for the special tool differ by country, so two types are provid- ed. Page 39 Dynamic spark tester YM Ignition checker This instrument is necessary for checking the igni- tion system components.
Pull it toward the handlebar to acti- vate the front brake. In this installation, make sure the arrow faces the fuel tank and also downward. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old. 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. Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows. Perform the pre-operation checks on the machine. Start and warm up the engine. Vor dem Starten des Motors, den 1.
Avant de lancer le moteur, rem- 1. Tighten all such fasteners as required. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. After cleaning the ma- chine thoroughly, prepare it for storage as fol- lows: 1. Torque specifications for special components or assem- blies are included in the applicable sections of this book.
To avoid warpage, tighten multi-faste- ner assemblies in a crisscross fashion, in pro- gressive stages, until full torque is reached. Le specifiche relative alla coppia per componenti o gruppi speciali sono incluse nelle se- zioni pertinenti di questo manuale. H Clamp the radiater breather 3 Cable guide to the frame. With the clamp 4 Clamp ends downward, tighten the hose and CDI magneto lead J Clamp the wireharness on 3 Brake hose absorber , correct its twist. Page Maintenance Intervals If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
Page Intervalli Di Manutenzione Se si hanno dubbi sugli interval- li da seguire per la manutenzione e la lubrificazione del veicolo, consultare il concessionario Yamaha. In base Before using this machine, check the following points.
Prima di usare questo veicolo, controllare i punti che seguono. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. If it splashes, wash it away with water.
Place a container under the engine. Remove: 9Coolant drain bolt 1 3. Remove: 9Radiator cap Drain the coolant completely. Handling notes of coolant: The coolant is harmful so it should be handled with special care. Inspect: 9Pressure Impossible to maintain the specified pres- sure for 10 seconds Repair. Check: 9Throttle grip free play a Out of specification Adjust.
Adjust: 9Throttle grip free play Throttle grip free play adjustment steps: 9Loosen the locknut 1. Install: Throttle cable cap 1 Nm 0. Never run the engine without the air filter element in place; Monter: 3.
Einbauen: 3. Inspect: Air filter element Damage Replace. Apply: Foam-air-filter oil or engine mixing oil To the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping. Examiner: 3.
Check: Transmission oil level Transmission oil level checking steps: Remove the oil check bolt 1. Inspect the oil level. NOTE: Be sure the machine is positioned straight up when inspecting the oil level. Never attempt to remove the oil check bolt just after high speed operation. Kontrollieren: 3. Remove: Oil drain bolt 1 Oil filler cap 2 Drain the transmission oil.
2001 yamaha yz125 service manual free download -
Always replace piston pin clips after one use. Replace distorted cir- clips. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite to the thrust 3 it receives.
Avant remontage, tous les circlips 1. Alle Sicherungsringe vor dem Wie- 1. Disconnect: 9 Connector 2. Dry each terminal with an air blower. Connect and disconnect the connector two or three times. Pull the lead to check that it will not come off. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and part number used for the special tool differ by country, so two types are provid- ed.
Page 39 Dynamic spark tester YM Ignition checker This instrument is necessary for checking the igni- tion system components. Pull it toward the handlebar to acti- vate the front brake. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old. 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.
Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows. Perform the pre-operation checks on the machine. Start and warm up the engine. Vor dem Starten des Motors, den 1. Avant de lancer le moteur, rem- 1. Tighten all such fasteners as required.
Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. After cleaning the ma- chine thoroughly, prepare it for storage as fol- lows: 1. Page 78 Ignition timing B. Torque specifications for special components or assem- blies are included in the applicable sections of this book.
To avoid warpage, tighten multi-faste- ner assemblies in a crisscross fashion, in pro- gressive stages, until full torque is reached. Wenn Teile mit mehreren Befestigungselementen festgezogen werden, die Schrauben und Muttern kreuzweise und in meh- reren Schritten Le specifiche relative alla coppia per componenti o gruppi speciali sono incluse nelle se- zioni pertinenti di questo manuale.
K Clamp to the frame the CDI magneto lead and radiator breather hose. Take care to clamp them above the projec- tion on the frame. B Pass the brake hose into the brake hose hold- ers. Page Maintenance Intervals If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Nach Nach Page Intervalli Di Manutenzione Se si hanno dubbi sugli interval- li da seguire per la manutenzione e la lubrificazione del veicolo, consultare il concessionario Yamaha.
In base Before using this machine, check the following points. Prima di usare questo veicolo, controllare i punti che seguono. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. If it splashes, wash it away with water. Place a container under the engine. Remove: 9 Coolant drain bolt 1 3. Remove: 9 Radiator cap Drain the coolant completely.
Handling notes of coolant: The coolant is harmful so it should be handled with special care. Examiner: 4. Adjust: 9 Throttle grip free play Throttle grip free play adjustment steps: 9 Loosen the locknut 1. Install: 9 Throttle cable cap 1 Nm 0. Never run the engine without the air filter element in place; Monter: 3.
Einbauen: 3. Apply: 9 Foam-air-filter oil or equivalent oil To the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping.
Examiner: 3. Check: 9 Transmission oil level Transmission oil level checking steps: 9 Remove the oil check bolt 1. NOTE: Be sure the machine is positioned straight up when inspecting the oil level.
Never attempt to remove the oil check bolt just after high speed operation. Kontrollieren: 3. Remove: 9 Oil drain bolt 1 9 Oil filler cap 2 Drain the transmission oil. Install: 9 Aluminum washer 9 Oil drain bolt 1 20 Nm 2. Ausbauen: 4. Start the engine and thoroughly warm it up. Adjust: 9 Idle speed Adjustment steps: 9 Loosen the locknut 1. Install: 9 Bolt fiber 1 10 Nm 1.
A dangerous loss of braking performance may occur if the brake system is not properly bled. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.
Add brake fluid to the level line on the reservoir. Brake pedal height a a : Zero mm Zero in NOTE: The brake pedal height is the vertical distance from the inside top end of the footrest.
Pad pin plug: 3 Nm 0. NOTE: Replace the drive, driven sprockets and drive chain as a set. Examiner: 1. Check: 9 Drive chain stiffness a Clean and oil the chain and hold as illustrated. Install: 9 Drive chain 1 9 Joint 2 9 Master link clip 3 Be sure to install the master link clip to the direction as shown. Kontrollieren: 4. Adjust: 9 Drive chain slack Drive chain slack adjustment steps: 9 Loosen the axle nut 1 and locknuts 2.
Einstellen: 3. Elevate the rear wheel by placing the suit- able stand under the engine. Remove: 9 Rear frame 3. Loosen: 9 Locknut 1 4. Adjust: 9 Spring preload By turning the adjuster 2. Tighten: 9 Locknut 6. Install: 9 Rear frame upper 32 Nm 3. Serrer: 5. Festziehen: 5. Monter: 6. Einstellen: 6. Adjust: 9 Low compression damping force By turning the adjuster 1. Turn the ad- juster 1 1 in. Adjust: 9 High compression damping force By turning the adjuster 1.
Standard tire pressure: kPa 1. Elevate the front wheel by placing a suitable stand under the engine. Check: 9 Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth. Examiner: 2. Avoid over-tightening. Ring nut final tightening : 7 Nm 0. Remove: 9 Spark plug 2. Togliere: 1. Ausbauen: 9 Candela 2.
Ausbauen: 1. Adjust: 9 Ignition timing Adjustment steps: 9 Loosen the screws stator 1. Screw stator : 7 Nm 0. Einstellen: 7. Remove: 1. Scalding hot fluid and steam may be blown out under pressure, which could cause serious in- jury. When the engine has cooled, open the ra- diator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter Install: 9 Radiator breather hose 1 9 Radiator hose 3 2 2 Nm 0.
NOTE: Clamp the radiator hose in the direction as shown. Needle holder Jet needle Float chamber Needle jet cover Remove: 9 Throttle valve 1 9 Ring 2 9 Spring throttle valve 3 9 Mixing chamber top NOTE: 9 Use a petroleum based solvent for cleaning.
Blow out all passages and jets with com- pressed air. NOTE: Inspect the filter as it is assembled to the carbu- retor. Do not remove the filter except when replacing it. EC Fuel level 1. Ispezionare: 1. EC Reed valve 1. Reed valve bending limit: 0. IC Soupape flexible Zungenventil Valvola a lamella 1. Install: 9 Reed valve assembly 1 9 Reed valve spacer 2 3. Install: 9 Carburetor joint 1 9 Bolt carburetor joint 2 10 Nm 1.
Install: 9 Throttle stop screw 1 9 Locknut 2 9 Pilot air screw 3 Note the following installation points Monter: 2. Einbauen: 2. Installare: 9 Ens. Install: 9 Throttle cable 1 9 Locknut 2 4 Nm 0. Monter: 7. Einbauen: 7. Tighten: 9 Bolt air filter joint 1 2 Nm 0. Serrer: 2. Festziehen: 2. EC Piston and piston ring 1. Eliminate: 9 Carbon deposits Use a rounded scraper 1. NOTE: Take care to avoid damaging the spark plug threads. Do not use a sharp instrument.
Avoid scratching the aluminum. Entfernen: 1. Einen abgerundeten Schaber Usare un raschietto arrotondato 1 verwenden. Do not rebore the cylinder. Measure: 9 Piston pin outside diameter Use micrometer 1. Install: 9 Piston ring Into the cylinder. Push the ring with the piston crown. Measure: 9 End gap Use a thickness gauge 1.
Monter: 1. Installare: 9 Fascia elastica 9 Segment 9 Kolbenring Dans le cylindre. In Zylinder. Nel cilindro.
Pousser le segment avec la Den Kolbenring mit dem Kol- Spingere la fascia con la corona calotte du piston. Check: 9 Cylinder mark a Cylinder mark a a Cylinder size Apply: 9 Engine oil To piston 1, piston ring 2 and cylinder surface. Install: 9 Cylinder 1 Make sure the piston ring is properly posi- tioned.
Install the cylinder with one hand while compressing the piston ring with the other hand. Appliquer: 1. Auftragen: 1. Install: 9 Gasket power valve housing 9 Power valve housing 1 9 Bolt power valve housing 2 4 Nm 0. Monter: 5. Einbauen: 5. Measure at all four points. Mesurer: 1. Messen: 1. Einbauen: 1. Install: 9 Friction plate 1 9 Clutch plate 2 NOTE: 9 Install the clutch plates and friction plates alter- nately on the clutch boss, starting with a friction plate and ending with a friction plate.
Install: 9 Doewl pin 1 9 Gasket cluch cover 2 Install: 9 Clutch cover 1 9 Bolt clutch cover 2 10 Nm 1. Monter: Einbauen: Loosen: 9 Bolt primary drive gear 1 NOTE: Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3. EC4B Kick axle assembly 1. Use a spring gauge 1. Kick clip friction force: 0. Install: 9 Torsion spring 1 9 Stopper lever 2 9 Bolt stopper lever 3 10 Nm 1. Install: 9 Bolt shift guide 1 10 Nm 1.
Monter: 4. Einbauen: 4. EC4C Kick idle gear 1. Crocher: 4. Haken: 4. Agganciare: 9 Ressort de torsion 1 9 Torsionsfeder 1 9 Molla di torsione 1 N. Install: 9 Crankcase cover right 1 NOTE: Mesh the governor gear 2, and impeller shaft gear 3 with primary drive gear 4. Install: 9 Bolt [crankcase cover right ] 1 10 Nm 1. EC4K Bearing 1. Install: 9 Ball 1 9 Retainer 2 To governor shaft 3. NOTE: Apply the transmission oil on the retainer and ball.
Zur Reglerachse 3. EC4H Bearing 1. Inspect: 9 Bearing 1 Rotate inner race with a finger. EC Oil seal 1. Install: 9 Impeller shaft assembly1 NOTE: 9 Take care so that the oil seal lip is not damaged or the spring does not slip off its position.
Remove: 9 Nut rotor 1 9 Plain washer 2 Use the rotor holding tool 3. Remove: 9 Rotor 1 Use the flywheel puller 2. Install: 9 Gasket [crankcase cover left ] 9 Crankcase cover left 1 9 Screw [crankcase cover left ] 2 5 Nm 0. Connecter: 7. Install: 9 Engine 1 Install the engine from right side. Install: 9 Lock washer 1 9 Nut drive sprocket 2 75 Nm 7. Bend the lock washer tab to lock the nut.
Install: 9 Chain guide 1 9 Chain cover 2 9 Screw chain cover If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when removing the bolt. Turn the throttle stop screw 2 until the engine runs at the lowest possible speed. Tighten the locknut. Install: Bolt fiber 1 10 Nm 1. A dangerous loss of braking performance may occur if the brake system is not properly bleed. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.
Add brake fluid to the level line on the reservoir. Check: 9 Brake pedal height a Out of specification Adjust. Brake pedal height a a : 5 mm 0. Adjust: 9 Brake pedal height Pedal height adjustment steps: 9Loosen the locknut 1. Pad pin plug: 3 Nm 0. Check: 9Brake lever operation A softy or spongy feeling Bleed brake system. Inspect: 9 Rear brake pad insulator 1 Damage Replace. Inspect: 9 Sprocket teeth a Excessive wear Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set.
Remove: 9 Master link clip 9 Joint 1 9 Drive chain 2 2. Examiner: 1. Install: 9 Drive chain 1 9 Joint 2 9 Master link clip 3 Be sure to install the master link clip to the direction as shown. Monter: 5. Einbauen: 5. Adjust: 9 Drive chain slack Drive chain slack adjustment steps: 9 Loosen the axle nut 1 and locknuts 2. Turn adjuster 3 3 counter- To tighten clockwise. Turn adjuster 3 3 clockwise To loosen and push wheel forward.
Einstellen: 3. The ad- juster may be damaged. Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. Elevate the rear wheel by placing the suit- able stand under the engine. Remove: 9 Rear frame 3.
Loosen: 9 Locknut 1 4. Adjust: 9 Spring preload By turning the adjuster 2. Adjust: 9 Rebound damping force By turning the adjuster 1. Stiffer a a Increase the rebound damping force. Turn the adjuster 1 1 in. Softer b b Decrease rebound Adjust: 9 Low compression damping force By turning the adjuster 1. Stiffer a a Increase the low compression damping force. Turn the ad- juster 1 1 in. Softer b b Decrease the low compres Adjust: 9 High compression damping force By turning the adjuster 1.
Stiffer a a Increase the high compression damping force. Softer b b Decrease the high compres Measure: 9 Tire pressure Out of specification Adjust. Standard tire pressure: kPa 1. Inspect: 9 Bearing free play Exist play Replace. Elevate the front wheel by placing a suitable stand under the engine. Check: 9 Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth. Examiner: 2. Avoid over-tightening. Ring nut final tightening : 7 Nm 0. Remove: 9 Spark plug 2.
Distinctly different color Check the engine condition. Togliere: 1. Ausbauen: 9 Candela 2. Ausbauen: 1. Adjust: 9 Ignition timing Adjustment steps: 9 Loosen the screws stator 1. Screw stator : 8 Nm 0.
Einstellen: 7. Remove: 9 Side cover left and right 1 Be sure to remove the seat before remov- ing the side cover. If you remove the side cover with force without removing the seat, 2 2 on the inside may contact the panel the air cleaner case and come off. Scalding hot fluid and steam may be blown out under pressure, which could cause serious in- jury. When the engine has cooled, open the ra- diator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counter Install: 9Radiator breather hose 1 9Radiator hose 3 2 1 Nm 0.
NOTE: Install the radiator hose 3 with its shorter pro- truding length a from the protector 5 on the ra- diator side. Remove: 9 Throttle valve 1 9 Ring 2 9 Spring throttle valve 3 9 Mixing chamber top NOTE: 9 Use a petroleum based solvent for cleaning.
Blow out all passages and jets with com- pressed air. Inspect: 9Filter 1 Damage Replace. NOTE: Inspect the filter as it is assembled to the carbu- retor. Do not remove the filter except when replacing it. EC Fuel level 1. Measure: 9Fuel level a Out of specification Adjust. Ispezionare: 1. Danni Sostituirlo. Endommagement Changer. Inspect: 9Float 1 Damage Replace. EC Reed valve 1. Measure: 9Reed valve bending a Out of specification Replace.
Reed valve bending limit: 0. IC Soupape flexible Zungenventil Valvola a lamella 1. Install: 9Reed valve assembly 1 9Reed valve spacer 2 NOTE: Install the reed valve spacer with its wider con- tact surface side a to the right. Install: 9Carburetor joint 1 9Bolt carburetor joint 2 10 Nm 1.
Monter: 2. Einbauen: 2. Installare: 9 Ens. Monter: 7. Einbauen: 7. Tighten: 9Screw air filter joint 1 9Screw carburetor joint 2 3. Serrer: 2.
Festziehen: 2. EC Piston and piston ring 1. Remove: 9Carbon deposits Use a rounded scraper 1. NOTE: Take care to avoid damaging the spark plug threads. Do not use a sharp instrument. Avoid scratching the aluminum. Einen abgerundeten Schaber Usare un raschietto arrotondato 1 verwenden.
Inspect: 9Cylinder inner surface Score marks Repair or replace. Do not rebore the cylinder. Out of limit Replace. Inspect: 9Piston pin 9Small end bearing Signs of heat discoloration Replace. Measure: 9Piston pin outside diameter Use micrometer 1. Install: 9Piston ring Into the cylinder. Push the ring with the piston crown. Measure: 9End gap Use a thickness gauge 1. Monter: 1. Installare: 9 Fascia elastica 9 Segment 9 Kolbenring Dans le cylindre.
In Zylinder. Nel cilindro. Pousser le segment avec la Den Kolbenring mit dem Kol- Spingere la fascia con la corona calotte du piston. Check: 9Cylinder mark a Cylinder mark a a Cylinder size Carbon deposits Remove.
EC Power valve hole on cylinder 1. Remove: 9 Carbon deposits From power valve hole surface a. Apply: 9Engine oil To piston 1, piston ring 2 and cylinder surface. Install: 9Cylinder 1 Make sure the piston ring is properly posi- tioned. Install the cylinder with one hand while compressing the piston ring with the other hand. Appliquer: 1. Auftragen: 1. Install: 9Gasket power valve housing 9Power valve housing 1 9Bolt power valve housing 2 5 Nm 0.
Measure: 9Friction plate thickness Out of specification Replace friction plate as a set. Measure at all four points. Mesurer: 1. Messen: 1. Monter: in ] 1 1. Install: 9Friction plate 1 1 9Clutch plate 2 9Friction plate 2 3 NOTE: 9Install the clutch plates and friction plates alter- nately on the clutch boss, starting with a friction plate and ending with a friction plate. Install: 9 Clutch cover 1 9 Bolt clutch cover 2 10 Nm 1. Monter: 9. Einbauen: 9. Install: 9Plain washer 1 9 Circlip 2 Monter: 4.
Einbauen: 4. Installare: 9 Rondelle ordinaire 1 9 Rossetta 1 9 Beilegescheibe 1 9 Circlip 2 9 Sprengring 2 9 Anello elastico di arresto 2 Loosen: 9Bolt primary drive gear 1 NOTE: Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3.
EC4B Kick axle assembly 1. Measure: 9Kick clip friction force Out of specification Replace. Use a spring gauge 1. Kick clip friction force: 0. Install: 9Bolt shift guide 1 10 Nm 1. EC4C Kick idle gear 1. Crocher: 4. Haken: 4. Agganciare: 9 Ressort de torsion 1 9 Molla di torsione 1 9 Torsionsfeder 1 N.
Install: 9Bolt [crankcase cover right ] 1 10 Nm 1. EC4K Bearing 1. Install: 9Ball 1 9Retainer 2 To governor shaft 3. NOTE: Apply the transmission oil on the retainer and ball. EC4H Bearing 1. Inspect: 9Bearing 1 Rotate inner race with a finger. EC Oil seal 1. Install: 9Impeller shaft 1 NOTE: 9Take care so that the oil seal lip is not dam- aged or the spring does not slip off its position.
Einbauen: 1. Remove: 9Nut rotor 1 9Plain washer 2 Use the rotor holding tool 3. Remove: 9Rotor 1 Use the flywheel puller 2. Install: 9Gasket [crankcase cover left ] 9Crankcase cover left 1 9Screw [crankcase cover left ] 2 5 Nm 0. Connecter: 7. Install: 9Engine 1 Install the engine from right side.
Install: 9Lock washer 1 9Nut drive sprocket 2 60 Nm 6. Bend the lock washer tab to lock the nut. Install: 9Chain cover 1 9Screw chain cover 2 5 Nm 0. EC4N Crankcase 1. Remove: 9Crankcase right 1 Use the crankcase separating tool 2 and crankcase separating bolt 3. Remove: 9Crankshaft 1 Use the crankcase separating tool 2 and crankcase separating bolt 3.
EC4N Crankshaft bearing 1. Inspect: 9Bearings 1 Rotate inner race with a finger. Inspect: 9Oil seal 1 Damage Replace.
EC4N Crankshaft 1. Measure: 9Runout limit a 9Small end free play limit b 9Connecting rod big end side clearance c 9Crank width d Out of specification Replace. Page Unsmooth operation Repair. Install: 9Dowel pin 1 9O-ring 2 9Crankcase right 3 To crankcase left 4. Install: 9Holder 1 9Bolt holder 2 10 Nm 1. Install: 9Segment 1 9Bolt segment 2 30 Nm 3. Monter: 6. Einbauen: 6. Note the position of each part. Pay particular attention to the lo- cation and direction of shift forks.
Ausbauen: 9 Axe principal 1 9 Asse principale 1 9 Hauptwelle Check: 9Shift fork movement On its guide bar. Install: 92nd wheel gear 28T 1 96th wheel gear 24T 2 94th wheel gear 27T 3 93rd wheel gear 26T 4 95th wheel gear 26T 5 91st wheel gear 30T 6 To drive axle 7. NOTE: 9Apply the molybdenum disulfide oil on the 1st, 2nd, 3rd and 4th wheel gears inner circumfer EC Wheel bearing if necessary 1.
Togliere: 9 Roue 1 9 Rad 1 9 Ruota 1 N. Measure: 9Wheel axle bends Out of specification Replace. Use the dial gauge 1.
Wheel axle bending limit: 0. Install: 9Nut wheel axle 1 Nm Tighten: 9Bolt axle holder 1 23 Nm 2. Installare: 9 Axe de roue 1 9 Asse della ruota 1 9 Radachse 1 N. Install: 9Bearing right 1 9Circlip 2 9Spacer Installare: 9 Couvercle de tuyau 1 9 Copertura del tubo flessibile 1 9 Schlauchdeckel 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 9 Boulon 9 Schraube Install: 9Driven sprocket 1 9Bolt driven sprocket 2 9Plain washer driven sprocket 3 9Nut driven sprocket 4 42 Nm 4.
Monter: 8. Einbauen: 8. A Front B Rear 2. Connect the transparent hose 1 to the bleed screw 2 and place a suitable contain- er under its end. Never attempt to pry out piston seals and dust seals. Togliere: 9 Parapolvere 1 9 Joint de piston 2 9 Kolbendichtung Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled. Install: 9Piston seal 1 9Dust seal 2 Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly.
A Front B Rear 3. Install: 9Copper washer 1 9Union bolt 2 30 Nm 3. Install the brake hose so that its pipe por- tion a a directs as show and lightly touches the projection b b on the caliper. Install: 9Disc cover 1 9Bolt disc cover 2 7 Nm 0. Install: 9Copper washer 1 9Brake hose 2 9Union bolt 3 30 Nm 3. Install the brake hose to the caliper with the paint a a on the pipe facing the caliper and with the pipe contacting the caliper Clean: 9Master cylinder 9Master cylinder kit Clean them with brake fluid.
Install: 9Master cylinder cup primary 1 9Master cylinder cup secondary 2 To master cylinder piston 3. NOTE: Apply the brake fluid on the master cylinder cup. Nettoyer: 1. Reinigen: 1. Install: 9Brake lever 1 9Bolt brake lever 2 6 Nm 0. Installare: 9 Levier de frein 1 9 Leva di comando del freno 1 9 Bremshebel 1 9 Boulon levier de frein 2 9 Schraube Bremshebel 2 9 Bullone leva di comando del freno EC5A Front brake hose 1.
Install: 9Brake hose 1 10 Nm 1. Install the brake hose so that its pipe por- tion a a directs as show and lightly touches the projection b b on the master cylinder. Install: 9Brake hose holder 1 9Screw brake hose holder 2 4 Nm 0. If it does, correct its twist. Installare: 9 Support de tuyau de frein 1 9 Supporto del tubo flessibile del 9 Bremsschlauchhalter 1 9 Vis support de tuyau de frein 2 9 Schraube Bremsschlauchhal- freno 1 ter Inspect: 9Brake fluid level Fluid at lower level Fill up.
So it is recommended that the front fork be maintained at the dealers. To prevent an accidental explosion of air, the following instructions should be ob- served: 9 The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to Daher wird N.
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