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ASSEIVIBLY MANUAL KIT

NTIGE D'SSEIVIBLAGE KIT


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