Manuel d'utilisation / d'entretien du produit 5HN-28199-13 du fabricant Yamaha
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TT-R90R 5HN-28199-13 LIT-11626-16-27 OWNER’S SERVICE MANUAL.
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EC010000 TT-R90R OWNER’S SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited.
INTRODUCTION Congratulations on your purchase of a Yamaha TT-R90R. 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.
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IMPORTANT NOTICE This machine is designed for off-road use only by young operators under adult instruction and supervision. It is illegal for this machine to be operated on any public street, road, or high- way. Off-road use on public lands may be illegal.
4. When transporting the machine in another vehicle, be sure is kept upright and that the fuel cock is turned to the “ OFF ” . If it should lean over, gasoline may leak out of the car- buretor or fuel tank. 5. Never start your engine or let it run for any length of time in a closed area.
SAFETY INFORMATION 1. Don ’ t ride it on the street. 2. Don ’ t run the engine inside a building. 3. This is a one-seater motorbike. Don ’ t give any person a ride. 4. Let ’ s learn how to ride properly. Ask your parents for any question. 5. When riding the machine, be sure to wear the protective apparel as illustrated.
6. When going for riding, be sure to be with your family. Never go alone. 7. Before riding the machine, ask your par- ents to check the machine very carefully. 8. Don ’ t touch the areas shown, or you ’ ll get burnt in the hand. 9. Don ’ t touch rotating or moving parts.
EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
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.
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 6 are designed as thumb tabs to indicate the chapter ’ s number and content. 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical Illustrated symbols 7 to D are used to identify the specifications appearing in the text.
INDEX GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE ENG 4 CHASSIS CHAS 5 ELECTRICAL ELEC 6 GEN INFO INSP ADJ – +.
CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......................................... 1-1 MACHINE IDENTIFICATION .................... 1-2 IMPORTANT INFORMATION ................... 1-3 CHECKING OF CONNECTION ................. 1-5 SPECIAL TOOLS .
CHAPTER 4 ENGINE CARBURETOR ......................................... 4-1 CYLINDER HEAD ..................................... 4-8 CAMSHAFT AND ROCKER ARMS ........ 4-13 VALVES AND VALVE SPRINGS ........... 4-16 CYLINDER AND PISTON ....................
1 - 1 GEN INFO DESCRIPTION EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 “ ENGINE STOP ” button 2 Front brake lever 3 Throttle grip 4 Fuel tank cap 5 Kick starter 6 Fuel tank 7 Air cleaner 8.
1 - 2 GEN INFO MACHINE IDENTIFICATION EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for posi- tive identification of the model you own.
1 - 3 GEN INFO IMPORTANT INFORMATION EC130000 IMPORTANT INFORMATION EC131002 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.
1 - 4 GEN INFO IMPORTANT INFORMATION EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is over- hauled.
1 - 5 GEN INFO IMPORTANT INFORMATION/ CHECKING OF CONNECTION EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlip 1 , make sure that the sharp-edged cor- ner 2 is positioned opposite to the thrust 3 it receives.
1 - 6 GEN INFO SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.
1 - 7 GEN INFO SPECIAL TOOLS YM-1312-A, 90890-01312 Fuel level gauge This gauge is used to measure the fuel level in the float chamber. YM-1312-A 90890-01312 YM-1326, 90890-01326 T-handle This tool is used for holding the damper rod holder when removing or installing the damper rod holder.
1 - 8 GEN INFO SPECIAL TOOLS YU-33270-B, 90890-01362 Flywheel puller This tool is used to remove the rotor. YU-33270-B 90890-01362 ACC-QUICK-GS-KT 90890-85505 Quick gasket ® YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc.
1 - 9 GEN INFO CONTROL FUNCTIONS EC150000 CONTROL FUNCTIONS “ ENGINE STOP ” SWITCH Make sure that the engine stop switch 1 is positioned to “” . The engine stop switch has been equipped to ensure safety in an emer- gency such when the machine is up set or trouble takes place in the throttle system.
1 - 10 GEN INFO CONTROL FUNCTIONS EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to acti- vate the front brake. EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine.
1 - 11 GEN INFO CONTROL FUNCTIONS/FUEL FUEL TANK CAP Remove the fuel tank cap 1 by turning counter-clockwise. W ARNING Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. FUEL Use regular gasoline. Always use fresh, name brand gasoline.
1 - 12 GEN INFO STARTING AND OPERATION STARTING AND OPERATION CAUTION: Prior to operating the machine, perform steps listed in pre-operation check list. W ARNING Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time.
SPEC 2 - 1 EC200000 SPECIFICA TIONS EC211000 GENERAL SPECIFICA TIONS Model name: TT -R90R (USA, CDN, A US, NZ) TT -R90 (Europe , ZA) Model code number: 5HNB (USA) 5HNC (Europe, A US, NZ, ZA) 5HND (CDN) Dimensions: Ov erall length 1,525 mm (57.0 in) Ov erall width 605 mm (23.
SPEC 2 - 2 Oil capacity: Engine oil P er iodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt) T otal amount 1.0 L (0.88 Imp qt, 1.06 US qt) Air fi lter : W et type element Fuel: T ype Unleaded gasoline only (USA, A US and NZ) Regular unleaded gasoline only (CDN, Europe) Regular gasoline (ZA) T ank capacity 4.
SPEC 2 - 3 Brak e: F ront brake type Drum brake Operation Right hand operation Rear brak e type Drum brake Operation Right f oot operation Suspension: F ront suspension T elescopic f ork Rear suspensi.
SPEC 2 - 4 MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Cylinder head: W arp limit ---- 0.03 mm (0.0012 in) Cylinder : Bore size 47.000 ~ 47.005 mm (1.8504 ~ 1.8506 in) 47.05 mm (1.8524 in) Out of round limit ---- 0.05 mm (0.0020 in) Camshaft: Drive method Chain drive (left) ---- Cam dimensions Intake “ A ” 25.
SPEC 2 - 5 Cam chain: Cam chain type/No . of links 92RH2005-84M/84 ---- Cam chain adjustment method A utomatic ---- Rock er arm/rock er arm shaft: Shaft outside diameter 9.981 ~ 9.991 mm (0.3930 ~ 0.3933 in) 9.95 mm (0.3917 in) Rock er arm inside diameter 10.
SPEC 2 - 6 Stem runout limit ---- 0.02 mm (0.0008 in) V alv e seat width IN 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) EX 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) V alv e spring: F ree length IN 28.32 mm (1.11 in) 26.9 mm (1.06 in) EX 28.
SPEC 2 - 7 Piston: Piston to cylinder clearance 0.025 ~ 0.045 mm (0.0010 ~ 0.0018 in) 0.15 mm (0.0059 in) Piston size “ D ” 46.960 ~ 46.975 mm (1.8488 ~ 1.8494 in) ---- Piston ov er siz e (2nd) 47.5 mm (1.8701 in) ---- (4th) 48.0 mm (1.8898 in) ---- Measuring point “ H ” 4 mm (0.
SPEC 2 - 8 Crankshaft: Crank width “ A ” 42.95 ~ 43.00 mm (1.691 ~ 1.693 in) ---- Runout limit C ---- 0.03 mm (0.0012 in) Big end side clearance “ D ” 0.10 ~ 0.40 mm (0.0039 ~ 0.0157 in) 0.50 mm (0.02 in) Big end radial clearance “ E ” 0.010 ~ 0.
SPEC 2 - 9 Lubrication system: Oil fi lter type Wire mesh type ---- Oil pump type T rochoid type ---- Tip clearance “ A ” or “ B ” 0.15 mm (0.0059 in) 0.2 mm (0.0079 in) Side clearance 0.13 ~ 0.18 mm (0.0051 ~ 0.0071 in) 0.23 mm (0.0091 in) Housing and rotor clearance 0.
SPEC 2 - 10 P ar t to be tightened Thread size Q ’ ty Tightening torque Nm m • kg ft • lb Cylinder head nut M8 × 1.25 4 22 2.2 16 Cylinder head bolt M6 × 1.0 2 10 1.0 7.2 Spark plug M10 × 1.0 1 13 1.3 9.4 Camshaft sprock et co v er bolt M6 × 1.
SPEC 2 - 11 CHASSIS Item Standard Limit Steering system: Steering bear ing type Angular bearing ---- F ront suspension: F ront fork tra v el 110 mm (4.33 in) ---- F ork spr ing free length 425.1 mm (16.74 in) 417 mm (16.4 in) F ork spr ing fi tting length 415.
SPEC 2 - 12 Drum brake: F ront dr um brake type Leading, trailing ---- Rear drum brake type Leading, tr ailing ---- F ront dr um inside diameter 95 mm (3.74 in) 96 mm (3.78 in) Rear drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in) F ront lining thickness 3 mm (0.
SPEC 2 - 13 NOTE: ● 1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut wrench and turn the steering right and left a few times; then loosen the ring nut one turn. 2. Retighten the ring nut 1 Nm (0.1 m • kg, 0.
SPEC 2 - 14 EC212300 ELECTRICAL Item Standard Limit CDI: Magneto-model/manuf acturer F5HN 00/Y AMAHA ---- Source coil resistance (color) 688 ~ 1,032 Ω at 20 ˚ C (68 ˚ F) (Brown – Green) ---- Pic.
2 - 15 SPEC GENERAL TORQUE SPECIFICATIONS/ 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.
2 - 16 SPEC CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM 1 Crankcase breather hose 2 Wire harness 3 CDI magneto lead 4 Starter cable 5 Carburetor heating lead 6 Engine stop switch lead 7 Thermo switch .
2 - 17 SPEC CABLE ROUTING DIAGRAM 1 Cable guide 2 Brake cable 3 Throttle cable 4 Fuel tank breather hose 5 Engine stop switch lead 6 Air vent hose 7 Air intake duct 8 Ignition coil 9 Cable guide 0 Wir.
2 - 18 SPEC CABLE ROUTING DIAGRAM Å Pass the fuel tank breather hose through the cable guide. ı Pass the throttle cable and engine stop switch lead through the cable guide. Ç Pass the air vent hose through the hose guide. Î Fasten the CDI unit lead and rectifier/regulator lead with the plastic clamp.
3 - 1 INSP ADJ MAINTENANCE INTERVALS/ PERIODIC MAINTENANCE AND LUBRICATION EC300000 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication.
3 - 2 INSP ADJ PRE-OPERATION INSPECTION AND MAINTENANCE *: Since these items requires special tools data and technical skills, they should be serviced. * 1 : For USA SERVICE NOTES: No. 1. DRIVE CHAIN: In addition to tension and alignment, chain must be lubricated every 0.
3 - 3 INSP ADJ ENGINE/THROTTLE CABLE ADJUSTMENT/ AIR FILTER CLEANING EC350000 ENGINE THROTTLE CABLE ADJUSTMENT 1. Check: ● Throttle grip free play a Out of specification → Adjust.
3 - 4 INSP ADJ AIR FILTER CLEANING 1. Install: ● Air scoop (right) 1 2. Install: ● Air filter case cover 1 3. Clean: ● Air filter element Clean them with solvent. N OTE: After cleaning, remove the remaining solvent by squeezing the element. CAUTION: ● Do not twist the element when squeezing the element.
3 - 5 INSP ADJ ENGINE OIL LEVEL INSPECTION 1. Start the engine, warm it up for several minutes and wait for five minutes. 2. Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine. 3. Remove: ● Dipstick 1 4.
3 - 6 INSP ADJ ENGINE OIL REPLACEMENT (Except for USA and CDN) CAUTION: ● Do not add any chemical additives or use oils with a grade of CD a or higher. ● Do not use oils labeled “ ENERGY CON- SERVING II ” b or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage.
3 - 7 INSP ADJ PILOT AIR SCREW ADJUSTMENT 5. Install: ● Gasket ● Drain bolt New T R . . 20 Nm (2.0 m · kg, 14 ft · lb) 6. Fill: ● Crankcase Oil quantity: Periodic oil change: 0.8 L (0.70 Imp qt, 0.85 US qt) 7. Install: ● Dipstick 8. Inspect: ● Engine (for oil leaks) ● Oil level Refer to “ ENGINE OIL LEVEL INSPEC- TION ” .
3 - 8 INSP ADJ IDLE SPEED ADJUSTMENT/ VALVE CLEARANCE ADJUSTMENT IDLE SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Attach: ● Inductive tachometer To spark plug lead. 3. Adjust: ● Idle speed VALVE CLEARANCE ADJUSTMENT N OTE: ● The valve clearance should be adjusted when the engine is cool to the touch.
3 - 9 INSP ADJ VALVE CLEARANCE ADJUSTMENT 4. Check: ● Valve clearance Out of specification → Adjust. 5. Adjust: ● Valve clearance Valve clearance (cold): Intake valve: 0.05 ~ 0.09 mm (0.0020 ~ 0.0035 in) Exhaust valve: 0.08 ~ 0.12 mm (0.031 ~ 0.
3 - 10 INSP ADJ SPARK ARRESTER CLEANING (For USA) 6. Install: ● Tappet cover (intake side) 1 ● O-ring 2 N OTE: Apply the lithium soap base grease on the O-ring. 7. Install: ● Tappet cover (exhaust side) ● O-ring ● Spark plug ● Timing plug ● Crankshaft end cover N OTE: Apply the lithium soap base grease on the O-ring.
3 - 11 INSP ADJ CHASSIS/FRONT BRAKE ADJUSTMENT/ REAR BRAKE ADJUSTMENT CHASSIS FRONT BRAKE ADJUSTMENT 1. Check: ● Brake lever free play a Out of specification → Adjust. Free play (brake lever): 10 ~ 20 mm (0.39 ~ 0.79 in) (at brake lever end) a 2 1 2.
3 - 12 INSP ADJ 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 In the center between the drive axle and rear wheel axle. Out of specification → Adjust.
3 - 13 INSP ADJ FRONT FORK INSPECTION/REAR SHOCK ABSORBER INSPECTION/ REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT ● Tighten the wheel axle nut while pushing down the drive chain. T R . . Axle nut: 60 Nm (6.0 m • kg, 43 ft • lb) EC36C000 FRONT FORK INSPECTION 1.
3 - 14 INSP ADJ 4. To stiffen the spring preload, install the circlip 1 into the groove a . To soften the spring preload, install the circlip into the groove b . N OTE: Do not spread the circlip too much. 5. Install: ● Spring guide 1 N OTE: While compressing the spring, install the spring guide.
3 - 15 INSP ADJ SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION/ STEERING HEAD INSPECTION AND ADJUSTMENT SPOKES INSPECTION AND TIGHTENING 1. Inspect: ● Spokes 1 Bend/damage → Replace. Loose spoke → Retighten. 2. Tighten: ● Spokes N OTE: Be sure to retighten these spokes before and after break-in.
3 - 16 INSP ADJ STEERING HEAD INSPECTION AND ADJUSTMENT 3. Check: ● Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut. 4. Adjust: ● Steering ring nut Steering ring nut adjustment steps: ● Remove the front fender 1 .
3 - 17 INSP ADJ STEERING HEAD INSPECTION AND ADJUSTMENT CAUTION: Install the handlebar holder with its groove a facing outward, and tighten the bolts so that the gaps b are equal. T R . . Steering stem bolt: 40 Nm (4.0 m • kg, 2.9 ft • lb) Front fork cap bolt: 40 Nm (4.
3 - 18 INSP ADJ LUBRICATION LUBRICATION To ensure smooth operation of all compo- nents, lubricate your machine during setup, after break-in, and after every race.
3 - 19 INSP ADJ ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: ● Spark plug 2. Inspect: ● Electrode 1 Wear/damage → Replace. ● Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition.
4 - 1 ENG ENGINE CARBURETOR Extent of removal: 1 Carburetor removal Extent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank 1 Clamp (air filter joint) 1 Loosen the screw (air filter joint).
4 - 2 ENG CARBURETOR EC468000 CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q ’ ty Remarks CARBURETOR DISASSEMBLY 1 Throttle valve 1 2 Throttle.
4 - 3 ENG CARBURETOR Extent of removal Order Part name Q ’ ty Remarks A Float pin 1 B Float 1 C Needle valve 1 D Main jet 1 E Pilot jet 1 F Needle jet 1 G Throttle stop screw assembly 1 H Pilot air .
4 - 4 ENG CARBURETOR EC464000 INSPECTION Carburetor 1. Inspect: ● Carburetor body Contamination → Clean. NOTE: ● Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. ● Never use a wire. 2. Inspect: ● Main jet 1 ● Pilot jet 2 ● Needle jet 3 Damage → Replace.
4 - 5 ENG CARBURETOR EC464401 Jet needle 1. Inspect: ● Jet needle 1 Bends/wear → Replace. ● Clip groove Free play exists/wear → Replace. ● Clip position Float height 1. Measure: ● Float height a Out of specification → Adjust. Standard clip position: No.
4 - 6 ENG CARBURETOR EC464600 Float 1. Inspect: ● Float 1 Damage → Replace. ASSEMBLY AND INSTALLATION Carburetor 1. Install: ● Pilot air screw 1 Note the following installation points: ● Screw in the pilot air screw until it is lightly seated.
4 - 7 ENG CARBURETOR 1. Measure: ● Fuel level a Use a fuel level gauge 1 . Out of specification → Adjust. Fuel level gauge: YM-1312-A/90890-01312 Fuel level: 2 ~ 3 mm (0.
4 - 8 ENG 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, fuel tank and rear fender Exhaust pipe Carburetor Refer to “ CARBURETOR ” section.
4 - 9 ENG CYLINDER HEAD Extent of removal Order Part name Q ’ ty Remarks 10 Camshaft sprocket 1 Refer to “ REMOVAL POINTS ” . 11 Timing chain 1 12 Cylinder head 1 13 Gasket 1 14 Dowel pin 2 1.
4 - 10 ENG CYLINDER HEAD REMOVAL POINTS Cylinder head 1. 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.
4 - 11 ENG CYLINDER HEAD 4. Remove: ● Cylinder head NOTE: ● Loosen the bolts and nuts in their proper loosening sequence. ● Start by loosening each bolt and nut 1/2 turn until all are loose. ASSEMBLY AND INSTALLATION 1. Install: ● Cylinder head 2.
4 - 12 ENG CYLINDER HEAD CAUTION: . Do not turn the crankshaft during instal- lation of the camshaft. Damage or improper valve timing will result. ● Remove the safety wire from the timing chain. 4. Install: ● Washer ● Bolt 1 NOTE: Install the bolt 1 while holding the rotor nut with a wrench.
4 - 13 ENG CAMSHAFT AND ROCKER ARMS CAMSHAFT AND ROCKER ARMS Extent of removal: 1 Rocker arm 2 Camshaft removal Extent of removal Order Part name Q ’ ty Remarks CAMSHAFT AND ROCKER ARMS Preparation for removal Cylinder head Refer to “ CYLINDER HEAD ” section.
4 - 14 ENG CAMSHAFT AND ROCKER ARMS REMOVAL POINTS Rocker arm shaft 1. Remove: ● Rocker arm shafts NOTE: Use a slide hammer bolt 1 and weight 2 to slide out the rocker arm shafts. Slide hammer set: YU-1083-A Slide hammer bolt: 90890-01085 W eight: 90890-01084 INSPECTION Camshaft 1.
4 - 15 ENG CAMSHAFT AND ROCKER ARMS 3. Apply: ● Molybdenum disulfide oil (onto the rocker arm and rocker arm shaft) 4. Install: ● Rocker arm 1 ● Rocker arm shaft 2.
4 - 16 ENG VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Extent of removal: 1 Valves removal Extent of removal Order Part name Q ’ ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “ CYLINDER HEAD ” section.
4 - 17 ENG VALVES AND VALVE SPRINGS REMOVAL POINTS Valve removal 1. Remove: ● Valve cotters 1 NOTE: Attach a valve spring compressor 2 between the valve spring retainer and the cylinder head to remove the valve cotters. V alve spring compressor: YM-4019/90890-04019 INSPECTION Valve 1.
4 - 18 ENG VALVES AND VALVE SPRINGS Valve spring 1. Measure: ● Valve spring free length a Out of specification → Replace. 2. Measure: ● Spring tilt a Out of specification → Replace. Free length (valve spring): Intake: 28.32 mm (1.11 in) <Limit>: 26.
4 - 19 ENG VALVES AND VALVE SPRINGS 2. 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.
4 - 20 ENG VALVES AND VALVE SPRINGS ASSEMBLY AND INSTALLATION 1. Apply: ● Molybdenum disulfide oil (onto the valve stem and valve stem seal) 2. Install: ● Valve stem seats ● Valves ● Valve spr.
4 - 21 ENG CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: 1 Cylinder removal 2 Piston removal Extent of removal Order Part name Q ’ ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “ CYLINDER HEAD ” section.
4 - 22 ENG CYLINDER AND PISTON REMOVAL POINTS Piston 1. Remove: ● Piston pin clips 1 ● Piston pin 2 ● Piston 3 NOTE: ● Before removing the piston pin clip, cover the crankcase opening with a clean towel or rag to prevent the clip from falling into the crank- case cavity.
4 - 23 ENG CYLINDER AND PISTON Cylinder bore “ C ” 47.000 ~ 47.005 mm (1.8504 ~ 1.8506 in) Taper limit “ T ” 0.05 mm (0.002 in) Out of round “ R ” 0.
4 - 24 ENG CYLINDER AND PISTON Piston ring 1. Measure: ● Ring side clearance Use a feeler gauge. 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.
4 - 25 ENG CYLINDER AND PISTON Piston pin 1. Inspect: ● Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: ● Piston pin outside diameter ● Piston pin bore inside diameter ASSEMBLY AND INSTALLATION Piston 1.
4 - 26 ENG CYLINDER AND PISTON 2. Position: ● Top ring ● 2nd ring ● Oil ring Offset the piston ring end gaps as shown. a Top ring end b Oil ring end (lower) c Oil ring end (upper) d 2nd ring end 3. Install: ● Piston 1 ● Piston pin 2 ● Piston pin clips 3 NOTE: ● Apply engine oil onto the piston pin, piston ring and piston.
4 - 27 ENG CLUTCH CLUTCH CRANKCASE COVER (LEFT AND RIGHT) Extent of removal: 1 Crankcase cover (left) removal 2 Crankcase cover (right) removal Extent of removal Order Part name Q ’ ty Remarks CRANKCASE COVER (LEFT AND RIGHT) REMOVAL Preparation for removal Drain the engine oil.
4 - 28 ENG CLUTCH CLUTCH Extent of removal: 1 Friction plate and clutch plate removal 2 Clutch housing removal 3 Primary clutch removal Extent of removal Order Part name Q ’ ty Remarks CLUTCH REMOVA.
4 - 29 ENG CLUTCH Extent of removal Order Part name Q ’ ty Remarks 13 Spacer 1 14 Spacer 1 15 Primary clutch nut 1 Use special tool. Refer to “ REMOVAL POINTS ” .
4 - 30 ENG CLUTCH REMOVAL POINTS Clutch boss 1. Remove: ● Clutch boss nut 1 ● Lock washer 2 ● Clutch boss NOTE: Straighten the lock washer tab and use the clutch holding tool 3 to hold the clutch boss. Å For USA and CDN ı Except for USA and CDN Clutch holding tool: YM-91042/90890-04086 Å ı Primary clutch 1.
4 - 31 ENG CLUTCH EC484600 Clutch plate 1. Measure: ● Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2 . EC484400 Clutch spring 1. Measure: ● Clutch spring free length a Out of specification → Replace springs as a set.
4 - 32 ENG CLUTCH ASSEMBLY AND INSTALLATION Primary clutch 1. Install: ● Washer 1 ● Nut (primary clutch) 2 NOTE: Tighten the nut while holding the magneto rotor with the sheave holder 3 . Clutch 1. Install: ● Lock washer 1 ● Nut (clutch boss) 2 NOTE: Use the clutch holding tool 3 to hold the clutch boss.
4 - 33 ENG KICK AXLE KICK AXLE Extent of removal: 1 Kick axle removal 2 Kick axle disassembly Extent of removal Order Part name Q ’ ty Remarks KICK AXLE REMOVAL AND DISASSEMBLY Preparation for removal Crankcase cover (right) Refer to “ CLUTCH ” section.
4 - 34 ENG SHIFT SHAFT SHIFT SHAFT Extent of removal: 1 Shift shaft removal Extent of removal Order Part name Q ’ ty Remarks SHIFT SHAFT REMOVAL Preparation for removal Clutch housing and clutch carrier Refer to “ CLUTCH ” section.
4 - 35 ENG SHIFT SHAFT Extent of removal Order Part name Q ’ ty Remarks 14 Stopper lever 1 15 Torsion spring 1 16 Circlip 1 17 Plate washer 1 18 Torsion spring 1 19 Shift lever 1 1.
4 - 36 ENG OIL PUMP OIL PUMP Extent of removal: 1 Oil pump removal 2 Oil strainer removal 3 Oil pump disassembly Extent of removal Order Part name Q ’ ty Remarks OIL PUMP REMOVAL AND DIS- ASSEMBLY Preparation for removal Clutch housing and clutch carrier Refer to “ CLUTCH ” section.
4 - 37 ENG OIL PUMP Extent of removal Order Part name Q ’ ty Remarks 11 Oil pump cover 1 12 Dowel pin 2 13 Oil pump drive shaft 1 14 Pin 1 15 Inner rotor 1 16 Outer rotor 1 17 Rotor housing 1 3.
4 - 38 ENG OIL PUMP INSPECTION Oil pump 1. Measure: ● Tip clearance a (between the inner rotor 1 and the outer rotor 2 ) ● Side clearance b (between the outer rotor 2 and the rotor housing 3 ) Out of specification → Replace the oil pump assembly.
4 - 39 ENG CDI MAGNETO CDI MAGNETO Extent of removal: 1 Pickup coil/stator assembly removal 2 Rotor removal Extent of removal Order Part name Q ’ ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank Crankcase cover (left) Refer to “ CLUTCH ” section.
4 - 40 ENG CDI MAGNETO REMOVAL POINTS Rotor 1. Remove: ● Rotor nut 1 ● Washer 2 NOTE: ● Loosen the rotor nut while holding the rotor with sheave holder 3 . ● Do not allow the sheave holder to touch the projection on the rotor. Sheave holder: YS-1880-A/90890-01701 2.
4 - 41 ENG CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q ’ ty Remarks CRANKCASE SEPARATION AND CRANKSHAFT REMOVAL Preparation for removal Seat, fuel tank and rear fender Exhaust pipe Air filter case Carburetor Refer to “ CARBURETOR ” section.
4 - 42 ENG CRANKCASE AND CRANKSHAFT Extent of removal: 1 Timing chain removal 2 Crankcase separation 3 Crankshaft removal Extent of removal Order Part name Q ’ ty Remarks Shift shaft Refer to “ SHIFT SHAFT ” section. Oil pump and oil strainer Refer to “ OIL PUMP ” section.
4 - 43 ENG CRANKCASE AND CRANKSHAFT INSPECTION Crankshaft 1. Measure: ● Runout limit a ● Connecting rod big end side clearance b ● Connecting rod big end radial clear- ance c ● Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge.
4 - 44 ENG SHIFT FORK, SHIFT CAM AND TRANSMISSION SHIFT FORK, SHIFT CAM AND TRANSMISSION Extent of removal: 1 Shift fork, shift cam, main axle and drive axle removal 2 Main axle disassembly 3 Drive ax.
4 - 45 ENG SHIFT FORK, SHIFT CAM AND TRANSMISSION Extent of removal Order Part name Q ’ ty Remarks 10 3th pinion gear 1 11 Main axle 1 12 Circlip 1 13 Washer 1 14 Collar 1 15 1st wheel gear 1 16 3rd.
4 - 46 ENG SHIFT FORK, SHIFT CAM AND TRANSMISSION EC4H3000 REMOVAL POINTS Shift fork, shift cam and transmission 1. Remove: ● Shift forks ● Shift cam ● Drive axle assembly ● Main axle assembly NOTE: ● Tap lightly on the transmission drive axle and shift cam with a soft hammer to remove.
5 - 1 CHAS EC500000 CHASSIS FRONT WHEEL AND REAR WHEEL FRONT WHEEL AND FRONT BRAKE FRONT WHEEL AND REAR WHEEL Extent of removal: 1 Front wheel removal 2 Wheel bearing removal 3 Brake shoe plate assemb.
5 - 2 CHAS Extent of removal Order Part name Q ’ ty Remarks 10 Brake shoe 2 11 Brake camshaft lever 1 12 Brake camshaft 1 3 FRONT WHEEL AND REAR WHEEL.
5 - 3 CHAS FRONT WHEEL AND REAR WHEEL REAR WHEEL AND REAR BRAKE Extent of removal: 1 Rear wheel removal 2 Wheel bearing removal 3 Brake shoe plate assembly removal and disassembly Extent of removal Order Part name Q ’ ty Remarks REAR WHEEL REMOVAL W ARNING Support the machine securely so there is no danger of it falling over.
5 - 4 CHAS FRONT WHEEL AND REAR WHEEL Extent of removal Order Part name Q ’ ty Remarks 11 Collar (left) 1 12 Wheel drive hub assembly 1 13 Bearing 2 Refer to “ REMOVAL POINTS ” .
5 - 5 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC513201 Wheel bearing (if necessary) 1. Remove: ● Bearing 1 NOTE: Remove the bearing using a general bearing puller 2 . 1 1 2 1 EC594000 INSPECTION EC514100 Wheel 1. Measure: ● Wheel runout Out of limit → Repair/replace.
5 - 6 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 W ARNING Support the machine securely so there is no danger of it falling over. Preparation for removal Hold the machine by placing the suitable stand under the engine.
5 - 7 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 Preparation for disas- sembly Drain the fork oil. 1 Adjuster 1 2 Fork spring 1 3 Dust cover 1 4 Stopper ring 1 5 Bolt (damper rod) 1 Use special tool.
5 - 8 CHAS FRONT FORK REMOVAL POINTS Inner tube 1. Remove: ● Bolt (damper rod) NOTE: While holding the damper rod with the damper rod holder 1 and T-handle 2 , loosen the bolt (damper rod). Damper rod holder: YM-1300/90890-01294 T -handle: YM-1326/90890-01326 EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1.
5 - 9 CHAS HANDLEBAR EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q ’ ty Remarks HANDLEBAR REMOVAL 1 “ ENGINE STOP ” switch 1 2 Brake lever cable 1 Disconnect at the lever side. 3 Brake lever 1 4 Grip cap (lower) 1 5 Grip cap (upper) 1 6 Throttle cable 1 Disconnect at the throttle side.
5 - 10 CHAS STEERING EC560000 STEERING LS LS T R . . TIGHTENING STEPS: •T ighten ring nut. 38 Nm (3.8 m • kg, 27 ft • Ib) •Loosen it completely.
5 - 11 CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal 2 Rear shock absorber removal Extent of removal Order Part name Q ’ ty Remarks SWINGARM REMOVAL W ARNING Support the machine securely so there is no danger of it falling over.
5 - 12 CHAS SWINGARM Extent of removal Order Part name Q ’ ty Remarks 9 Cotter pin 1 10 Nut (tension bar) 1 11 Bolt (tension bar) 1 12 Tension bar 1 1.
6 - 1 – + ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 CDI magneto 2 CDI unit 3 Ignition coil 4 Spark plug 5 “ ENGINE STOP ” switch 6 Thermo switch 7 Carburetor heater 8 Rectifier/regulator COLOR CODE B .
– + ELEC 6 - 2 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.
6 - 3 – + ELEC IGNITION SYSTEM EC622001 SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (ignition checker 2 ) as shown. ● Spark plug cap 3 ● Spark plug 4 Å For USA and CDN ı Except for USA and CDN 3.
6 - 4 – + ELEC IGNITION SYSTEM EC626002 IGNITION COIL INSPECTION 1. Inspect: ● Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester ( – ) lead → Black lead 2 Primary coil resistance Tester selector position 0.
6 - 5 – + ELEC IGNITION SYSTEM 2. Inspect: ● Source coil resistance Out of specification → Replace. Tester (+) lead → Brown lead 1 Tester ( – ) lead → Green lead 2 Source coil resistance T.
– + ELEC 6 - 6 CARBURETOR HEATING SYSTEM CARBURETOR HEATING SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning carburetor heating system. NOTE: ● Remove the following parts before inspection. 1) Seat 2) Fuel tank ● Use the following special tools in this inspection.
6 - 7 – + ELEC CARBURETOR HEATING SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: ● Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CDI MAGNETO INSPECTION 1. Inspect: ● Source coil resistance Refer to “ IGNITION SYSTEM ” section.
6 - 8 – + ELEC CARBURETOR HEATING SYSTEM Å The thermo switch circuit is open. ı The thermo switch circuit is closed. Test step Water temperature Continuity 1 Less than 23 ± 3 ˚ C (73.4 ± 5.4 ˚ F) YES 2 More than 23 ± 3 ˚ C (73.4 ± 5.4 ˚ F) NO 3 More than 12 ± 4 ˚ C (53.
– + ELEC 6 - 9 NOISE REGULATION/MAINTENANCE RECORD NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal o.
PRINTED IN JAPAN 2002.04-3.0 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN.
Un point important après l'achat de l'appareil (ou même avant l'achat) est de lire le manuel d'utilisation. Nous devons le faire pour quelques raisons simples:
Si vous n'avez pas encore acheté Yamaha 5HN-28199-13 c'est un bon moment pour vous familiariser avec les données de base sur le produit. Consulter d'abord les pages initiales du manuel d'utilisation, que vous trouverez ci-dessus. Vous devriez y trouver les données techniques les plus importants du Yamaha 5HN-28199-13 - de cette manière, vous pouvez vérifier si l'équipement répond à vos besoins. Explorant les pages suivantes du manuel d'utilisation Yamaha 5HN-28199-13, vous apprendrez toutes les caractéristiques du produit et des informations sur son fonctionnement. Les informations sur le Yamaha 5HN-28199-13 va certainement vous aider à prendre une décision concernant l'achat.
Dans une situation où vous avez déjà le Yamaha 5HN-28199-13, mais vous avez pas encore lu le manuel d'utilisation, vous devez le faire pour les raisons décrites ci-dessus,. Vous saurez alors si vous avez correctement utilisé les fonctions disponibles, et si vous avez commis des erreurs qui peuvent réduire la durée de vie du Yamaha 5HN-28199-13.
Cependant, l'un des rôles les plus importants pour l'utilisateur joués par les manuels d'utilisateur est d'aider à résoudre les problèmes concernant le Yamaha 5HN-28199-13. Presque toujours, vous y trouverez Troubleshooting, soit les pannes et les défaillances les plus fréquentes de l'apparei Yamaha 5HN-28199-13 ainsi que les instructions sur la façon de les résoudre. Même si vous ne parvenez pas à résoudre le problème, le manuel d‘utilisation va vous montrer le chemin d'une nouvelle procédure – le contact avec le centre de service à la clientèle ou le service le plus proche.
