MANUAL DE ENSAMBLE KIT 5NG-F8107-WO BELGARD S.p.A. Via Tinelli, 67/69 - 20050 Gerno di Lesmo (MI) Telefono (039) 60961 - Rio. Aut. provided by http://www.bikemode.de 11/01/2006 YAMAH A ASSEMBLY MANUAL KIT NTIGE D'ASSEMBLAGE KIT MONTAGEANLEITUNG KIT MANUALE DI ASSEMBLAGGIO KIT MANUAL DE ENSAMBLE KIT WR 426F '2001 WR 400F '2001 provided by http://www.bikemode.de 11/01/2006 SYMBOLS USED IN ASSEMBLY MANUAL In Order la simplify descriptions in assembly manuat, the following Symbols ara used: ..JBSi ; Coat with grease <ft10 : Tighton to 10 Nm (10 Nm = 1.0 m-kg = 7.2 ft-lb) <EE. : Make a 5mm-dia, hole $38 : Frontward (of the v&hicle) A : Apply SE 10W30 motor oil : Componeni io elirninate Q : Componeni to re-use ^ : Appty a locking liquid (LOOTITE*). SYMBOLES EMPLOVES DNS LES NTIGES D'ASSEMBLAGE Af t n de si mpf i er les descript ions donn^es dan.s les notices d'assemblage, les symboles suivants soni employtfs: d : Enduire <le grais.se l : Sener 10 Nm ( l ONm = l . Om- kg - 7,2 fi-lh) <aa : Percer un xiu de 5 nun dt: diam^t rc <^l : Avant (du v^hicule) ^ : L^grement huile moleur SE 10W30 9 : Cumposiints a eHminer. Q : Composants a reut iliser. l : Appliquer un liquide hlot j it ant SYMBOLE DiE IN DER MONTAGEANLEIT- UNG VERWENDET WERDEN Um die Beschreibungen in den Montageanieitungen zu vereinfachen, werden die folgenden. Symbole verwendet; jgSi . Mit Fetl scdmieren i) 10 : Mit 10 Nm (estziehen (10 Nrn ^ 1,0 m-kg = 7,2 tt-lb) <IEQ : Ein Loch mit 5 mm Durchmesser bohren ^a : Vorderseite (des Fahrzeuges) ^ : Motorol SE 10W30 schmieren 9 ; Zu antfemenede Bestandteile Q : Wiederzuverwendende Bestandteile i : Eine (eslkfemmondB flssigkeit (LCTITE*) auftragen. SIMBOLI SATI IN QUESTO MANUALE AI fine di sernplif icare le descrizioni rif erit e al mont aggio dei vari cornponent i, sono st at i adottad i seguenli simboli: S- : Ingrassare ^10 : Serrare con coppia pari a ( ONm (~ I.Kgm) <on : Farc un foro di 5 mm di diiimfiio t^ai : Parte anteriore del vcicolo : Lubrifscarc con olio niotore SE IOW30 : Cumponenti da eliminarc Q : Componenli da ut ilizzare ^ : Appeare un liquido bloccaij te (LOCTITb*) SIM8OLOS EMPLEADOS EN EL MANUAL DE MONTAJE A lin de simplificar las dscripcionss del manual de monfaje s empiean fos simboloa siguienles. E. : Rcvestir con grasa i^i : Apreiar a 10 Nm (10 Nm - 1.0 m-kg) US : H ocer un orificio ds 5 mm de dimetro ^^3 : Parte deiantera (del vehiculo) ^ : Apliqua aceile de molr SE 10W3Q ^ : Componentes para eiiminar. j~~] : Componentes para fcutilizar. i :Apcar un Ifquido bloqueante (LOCTITE"). provided by http://www.bikemode.de 11/01/2006 FIG. 1 YAMAHA WR426F/40QF KIT (PARTS TO BE TAKEN OUT) REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 PART NO. 5BF-83550-00 5BF-83976-00 23X-83976-00 90101-10738 5GS-27315-00 90506-35473 90401-10172 5BE-1 11 66-00 4GY-2831V-00 5NG-83500-00 4GY-2832V-00 5BF-84330-00 5BF-84310-00 5BF-84319-00 95027-06010 90461-11099 97780-40010 DESCRIPTION SPEEDOMETER GABLE SWITCH , H ANDLE 1 SWITCH , H ANDLE 1 BOLT, H EXAGON LINK, S!DE STAND SPRING, TENSION BOLT, UNION PIPE, BREATH ER STAY, H EAD LIGH T 1 METER ASSY STAY, H EAD LIGH T 2 BODY ASSY H EAD LIGH T UNITASSY STAY, H EAD LIGH T 2 BOLT, FLG. CLAMP SCREW, TAPPING Q.TY REMARKS 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 provided by http://www.bikemode.de 11/01/2006 FIG. 1 YAMAH A WR426F/400F KIT (PARTS TO BE TAKEM OUT) *7 provided by http://www.bikemode.de 11/01/2006 FIG. 2 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) REF. NO. 1 2 3 4 5 6 7 8 PART NO. 5BF-H 3550-00 4SU-H 3371-00 9131L-06012 90185-06837 9290L-06600 5BF-H 3375-00 4GV-H 3936-00 5BF-H 2586-00 DESCRIPTION SPEEDO, GABLE H RN BOLT, hexagon socket head NUT, nylon WASH ER, piain H RN, BRKT. ASSY BAND, SWITCH CORD ASSY EXTN. WIRE H ARNESS Q.TY RESVIARKS 1 1 1 1 1 1 1 1 provided by http://www.bikemode.de 11/01/2006 FIG. 2 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) Arrange cable outwards. Orienter le cable vers l'exterieur. Kabel nach aussen richten. Orientare il cavo verso l'esterno. Orientar el cable hacia el exterior Lubricate grommet to facilitate cable insertion. Graisser le passe-cable pour faciliter le passage du cable. Tlle zur leichteren durchfhrung des Kabels schmieren. Lubrificare il passacavo per facilitare il passaggio del cavo. Lubrificar el pasacable para facilitar el pasaje del cable. provided by http://www.bikemode.de 11/01/2006 FIG. 3 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED} REF. NO. 1 2 3 4 5 6 7 8 9 10 PART NO. 5NG-F3432-00 5NG-F3451-00 5NG-H 252V-00 5BF-F3474-00 5BF-F3408-00 5CH -F348G-00 5CH -F3484-00 5CH -F3486-00 5CH -F3483-00 90387-062E2 DESCRIPTION STOPPER, strg., BOLT SCREW, special BRKT, main STEERING LOCK ASSY SPRING, pin action CAP, handle lock STAY, plate RIVET COLLAR Q.TY REMARKS 1 1 2 1 1 1 1 1 1 2 provided by http://www.bikemode.de 11/01/2006 FIG. 3 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) Screw head sheartorque 10 - 20/0 nm. Couple de cisaillage de la tete des vis 10+20/0 nm. Abscher-drehmoment Schraubenkopf 10 - 20/0 nm. ***' Coppia di tranciatura testa vite 10+2/0 N.M. par de corte cabeza tornillo 10+20/0 nm. LOCHTE 243 ThreadingM4 FileterM4 GewindescheneidenM4 Fi!ettareM4 FiletearM4 provided by http://www.bikemode.de 11/01/2006 FIG. 4YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 PART NO. 5CH -H 3320-01 5CH -H 3320-10 9131M-06016 5BF-H 3500-00 3TC-81 965-00 5CH -H 3310-01 5CH -H 3310-10 5BF-F831V-00 9571L-06300 3TY-83350-00 5BF-F832V-00 5CH -H 4330-00 5CH -H 4310-00 90387-06X02 9581L-06016 DESCRIPT10N FR. FLASH ER LIGHT ASSY 2 FR. FLASH ER LIGHT ASSY 2 BOLT, hexagon socket head METER ASSY SMOOTH ING CONDENSER FR. FLASH ER LIGH T ASSY 1 FR. FLASH ER LIGHT ASSY 1 STAY, head light 1 NUT, nylon FLASH ER RELAY STAY, headlight 2 BODY ASSY H EAD LIGHT, unit assy COLLAR BOLT, flg. Q.TY 1 1 2 1 1 1 1 1 2 1 1 1 1 2 2 REMARKS Alternative part (only for WR.426F) Alternative part (only for WR.426F) provided by http://www.bikemode.de 11/01/2006 FIG. 4 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) H ood pre-assembly, Preassemblage de la visiere Vormontage haube. Preassernbiaggio cupotino. preensamblado cupulita. Take care that brake pipe moves free in its seat. Veiller a ce que le tuyau du frein soit bre dans son ogement. Darauf achten, dass die bremsieitung frei in ihrem sitz ist. Fare attenzione ehe il tubo de! frerio sia libero neila sede. Poner atencin para que el tubo del freno este bre en su alojamiento. Reuse bushes from serial hood. Recuperer les bagues de la visiere de s Buchsen aus der serienmssigen verwenden. Recuperare le boccole dal cupolino di Serie. Recuperar los casquios de la cupulita de serie. haube wieder 11 provided by http://www.bikemode.de 11/01/2006 FIG. 5 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) REF. NO. PART NO. DESCRIPTION 1 5BF-H 3969-00 2. 4GV-H 3936-00 SWITCH , H ANDLE 5 BAND Q.TY REMARKS 1 3 provided by http://www.bikemode.de 11/01/2006 FIG. 5 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) Set wiring outside vottage reg u lato r Positionner ie ct'iblage s 1'exterieur du regulateur Die Verkabelung auf3en an dem Spannungsregler anlegen Posizionare il cablaggio esternamente a! regolatore Posicionarel cableo al externo del reguiator While assembling avoid intersections witti cabtes. Pendant Ie iTiontage eviter toute interference avec fes cables. Bei der montags darauf achten, dass keine berschneidungen mit den kabeln bestehen. Nel montaggio evitare interferenze con i cavi. En el montajo evitar interferencias con los cables, provided by http://www.bikemode.de 11/01/2006 FIG. 6 YAMAHA WR426F/400F KIT (PARTS TO BE ADDE) REF. NO. 1 2 3 4 5 6 7 8 9 10 PART NO. 5BF-F7315-00 5BF-F7317-00 90506-33X00 90501-20X01 4LW-F7351-00 5BF-F81 76-00 5BF-E1 166-00 5BF-E4438-00 5BF-E4454-00 2AJ-F31 92-00 DESCRIPTIOM LINK BOLT, special SPRING, tension SPRING, compression GUIDE, side stand CAUTION, STICKER PIPE BREATH ER CLIP, drain cleaner JT. BAND, SWITCH CORD Q.TY REMARKS 1 1 1 1 1 1 1 1 1 1 provided by http://www.bikemode.de 11/01/2006 FIG. 6 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) Degrease stand beiore applying adhesive. Degraisser le chevalet avant d'appiiquer l'adhesii Stnder vor dem auftragen des klebstoffs entfetten. Sgrassare il cavalletto prima dt appttcar e Tadesivo. ingrasar el caballete antes de aplicar el adhesivo. While assembling apply an oil frn on connection t o facitate its insertion. Pendant le montage, ajouter un voile d'huiie sur le manchen pour faciliter l'introduction. Eine dnne lschicht auf dem stutzen zur leichteren einfhrung bei der montage auftragen. Nel montaggio aggiungere un velo d'olio sui rnanicolto per facilitare l'introduzione. en el montaje agregar una peh'cula de aceite en el manguito para facilitar la introduccin. e careful that no traces of material rernaln intake connection. Veiiler a ce que les dechets de materiel n ! encrassent pas le manchon d'aspiration. Darauf achten, dass keine festen rckstnde im ansaugstutzen verbleiben. Fare attenzione ehe i residui di matehale non rimangano nel manicotto di aspirazione. Poner atencin para que los residuos de material no queden en el manguito de aspiracin. provided by http://www.bikemode.de 11/01/2006 FIG. 7 YAMAHA WR426F/40F KIT (PARTS TO BE ADDED) REF. NO. 1 2 3 4 5 6 PART NO. 5BF-F6280-00 5GS-E4591-00 5BF-H 2530-00 4GV-H 3936-00 90267-32X01 5NG-E4752-WO DESCRIPTION RR. VIEWMIRROR STOP,SCREW STOP SW. ASSY BAND, SWITCH CORD RIVET, blind PIPE Q.TY RESV1ARKS 2 1 1 1 3 1 provided by http://www.bikemode.de 11/01/2006 FIG. 7 YAWIAH A WR426F/400F KIT (PARTS TO BE ADDED) Arrangs cable downwards. Orienler vers le bas. Kabel nach unten richten. Orientare verso il basso. Orientar hacia abajo. Remove carburet t or prot et t ing cover Oter Ic couveicle de protection du carburatcur () Die Schut zabdeckung des Vergasers ent fernen TogUere protezione carburatore Quit ar tapa proteccin carburador (4) Apply LOCTITE 243 (weak thread securing) insicte spacer. Appliquej; le LOCTITE 243 sudaface interne de l'entretoise (freinc legeremet les filets). LOcrrrE243 (schwaches gewinde-feslklemmen) innerhalb des abstandsstcks auftragen. Airinterno del distanziale applicare LOcriTEa243 (i'rena filetti dcbole). En el interior det distanciador apiicar LOCTITE ? (frena roscas Hojas). Remove exhaust pipe clamp '!> Remove H.V. coil Disconnect connector Enkver le Collier du t uyau de dechaige (B) Eulever k boliine H.T. Detacliei ic coimccteur Die Schelle des Abflurohres abziehen Die H ochspannungsspule entfernen Den Verbiaer lsen Sfilaie fascetta tubo di scarico Togliere bubina A.T. Staecare comieore Extraer la abrazadera tubo de descarga Quitar la bobina A.T. Despegar el conector (fj) j Apply a tjood amount ot grease on accclerator control Graisscr abondainmenl la poulie de coiruntuxfc du ga?. Rillenschalbe zur gasregulierung reichlich einfetten. Ingrasaic abbondiintcrrtente la cartuwna cortiandn gas. Engrasar abundantemenle la polea do mando gas. Bleed rear brake System. Effectuer la vidange du circuit frein arriere. Hintere bremsanlage entlften. E^segutre spiirgo impiantn frctiu posteriorc. Efectuar expurgacln instalacin frcno posterior Remove carburettor selscrew Smearlhescrew i wilh LOCHTE 243 Tighten the new setscrew Reut all previously remoued parts into original positions Eulever la vis de (in de cour^e du carbnrat eur rej Appliqucr LOC'I'ITE 243 sur la vis i Visser la nonvellc vis de fin de conrse Remont er dans ics positions d'origine t ot it es les pieces piec6dent emment dernontees Die Anschlargschraube entfernen < s > LOCHTE 243 auf die Schraube geben Die neue Anschlagschraube einschrauben Alle zuvor ausggebauten Teile wieder in ihre ursprnglich Position mont ieren Togliere la vit e tine corsa carbiiratore fy Applicare LCTITE 243 sulla nuova vite eavvitarla Rimontare nelle posizioni originarie t ut t i i p.irlicolari precedentemente rimossi Quitar el tornillo de del carburador Applicar LOCTITE 243 en el tomillo Atornillar el nuevo tornillo de tope Remontar en Jas posiciones de origen todos los particulares anterionnente quitados provided by http://www.bikemode.de 11/01/2006 FIG. 8 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 PART NO. 5BF-F1 685-00 5BF-H 3340-00 5NG-H 3340-00 5BF-H 3330-00 5NG-H 3330-00 9131M-06025 9571 L-06300 9290L-06200 5BF-F1618-00 5BF-F1617-00 4SU-H 4745-00 9290L-05200 9570L-05300 3SH -H 4551-00 9290L-06200 9571 L-06300 9581M-06020 5CH -H 51 30-00 9290M-06600 90185-06830 9290L-06200 90111-06806 9290L-06200 90185-06837 9581M-06025 9581M-06035 9290L-06200 9571 L-06300 DESCRiPTlON BRKT. LICENSE RR. FLASH ER LIGH T ASSY 2 RR. FLASH ER LIGH T ASSY 2 RR. FLASH ER LIGH T ASSY 1 RR. FLASH ER LIGH T ASSY 1 BOLT, hexagon socket head NUT, nylon WASH ER, plain REINF. REINF. LICENSE LIGH T UNIT ASSY WASH ER, plain NUT, nylon BRKT. LICEMSE WASH ER, plain NUT, nylon BOLT, flange REAR REFLECTOR ASSY WASH ER, plain NUT, self-locking WASH ER, plain BOLT, button WASH ER, plain NUT, nylon BOLT, flange BOLT, fiange WASH ER, plain NUT, nyoln Q.TY REMARKS 1 1 1 Alternative part (only for WR.426F) 1 1 Alternative part (only for WR.426F) 2 2 2 1 1 1 2 2 1 2 2 2 1 2 1 3 2 2 2 1 1 2 2 provided by http://www.bikemode.de 11/01/2006 FIG. 8 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) 19 LOCHTE 243 4, l 17 Mark mudguard corresponding to plate bracket holas. Tracer le garde-boue en corrcspondance des trous du porte-plaque. Schutzblech den schildhaller-lchem entsprechend vorzeichnen. Tracciare il parafungo in coirispondenza dei fori de! por- tatarga. Trazar al guardabarro en correspondencia con los agujeros del portaplaca. ! N" 2 06,5 2( Number plate bracket pre-assembiy. -. Preassemblage du porte-plaque. Vormontage kennzeichenschlldhalter. 24 Preasscmblaggio portatarga. ' Pre ensamblaje portaplaca. 7 LOCTITE243 LOCHTE 243 18 LOCHTE 213 r Avoid squeezing cables while fitting plate bracket to mudguard. Eviter d'ecraser les cables au cours du montage du porte- plaque sur le garde-boue. Darauf achten, dass dra kabel bei der montags des schildhalters am Schutzblech nicht gequetscht werden. Evilare i schiacciare i cavi durarile il montaggio del por- tataiga sul parafango. Evitar aplastar los cables durante el montaje dei por- taplaca en el guardabarro. provided by http://www.bikemode.de 11/01/2006 FIG. 9 YAMAHA WR426F/400F KIT (PARTS TO BE ADDED) REF. NO. PART NO. DESCRIPTION Q.TY REMARKS 1 5NG-F1529-00 MOLE, FENDER 1 2 5NG-F171L-00 MOLE, SIDE COVER 4 provided by http://www.bikemode.de 11/01/2006 FIG. 9 YAMAH A WR426F/400F KIT (PARTS TO BE ADDED) O 2 S< 170mm 2 S-=170mm provided by http://www.bikemode.de 11/01/2006