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Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.http://www.bosport.be/newsletter/3m-3500-manual This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. Dieses Modell entspricht fort- culmine della vasta esperienza della. Off-road use on public lands may also be illegal. Please check local regulations before riding. 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. 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, con-. Dar- faisant le plein.If there is any question you have regarding this manual or your machine, please consult your Yamaha deal- EC070001 F.I.M. MACHINE WEIGHTS: Weights of machines without fuel. Les poids minimum admis pour les cross sono: GEWICHT DER F.I.M. The information has been complied to provide the mechanic with an easy to read, handy reference that contains com- prehensive 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.g., 9Bearings. General information INSP Specifications Regular inspection and adjustments Engine Chassis Electrical Tuning CHAS ELEC Illustrated symbols 8 to r are used to identify the specifications appearing in the text. When washing the machine with high pres- sured water, cover the parts as follows. 9Silencer end 9Air filter intake slit 9Water pump housing hole at the bottom. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. Bauteile zu verwenden.Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is posi- tioned opposite to the thrust 3 it receives.http://as-seferovic.com/images/bostitch-n57c-manual.pdf See the sectional view. 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. La forma e il numero categorico usati per l’utensile speciale sono diversi a seconda del paese, quindi vengono forniti due tipi. Continue pushing the “ENGINE STOP” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left handle- bar;. 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. In this installation, make sure the arrow faces the fuel tank and also downward. EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. 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. Mixing oil: Mixing ratio: Yamalube “2-R” 15:1 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “ENGINE STOP”. Tighten all such fasteners as required. 9When any of the following parts have been replaced, they must be broken in. After cleaning machine thoroughly, prepare it for storage as fol- lows: 1. Drain the fuel tank, fuel lines, and the carbu- retor float bowl. 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. I Position the CDI magneto lead 3 Brake hose correct its twist.queuemanagementsystems.com/wp-content/plugins/formcraft/file-upload/server/content/files/16273d1432c375---brk-41208-manual.pdf B Pass the “ENGINE STOP” button lead in the middle 4 “ENGINE STOP”. Before using this machine, check the following points. EC321000 GENERAL INSPECTION AND MAINTENANCE Item Routine Page. Prima di usare questo veicolo, controllare i punti che seguono. IC321000 ISPEZIONE E MANUTENZIONE GENERALI Voce. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: 9Coolant drain bolt 1 3. Remove: 9Radiator cap Drain the coolant completely. 4. Handling notes of coolant: The coolant is harmful so it should be handled with special care. Never run the engine without the air filter element in place;. NOTE: Squeeze out the excess oil. Element should be wet but not dripping. 5. Install: 9Filter guide 1 NOTE: Align the projection a on filter guide with the hole b in air filter element. 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. To increase idle speed Turn the throttle stop screw 1 1 in. 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. j. Add brake fluid to the level line on the reservoir. Brake pedal height a a: 5 mm (0.20 in) 2. Adjust: 9Brake pedal height Pedal height adjustment steps: 9Loosen the locknut 1. NOTE: Replace the drive, driven sprockets and drive chain as a set. EC369002 DRIVE CHAIN INSPECTION 1. Remove: 9Master link clip 9Joint 1 9Drive chain 2 2. Turn adjuster 3 3 clockwise To loosen and push wheel forward. 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.Standard position: 14 clicks out Do not force the adjuster past the minimum or maximum extent of adjustment. The ad- juster may be damaged.anxuetang.com/upload/files/compaq-armada-1598dmt-manual.pdf EC36U013 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: 9Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth. Avoid over-tightening.Distinctly different color Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in. If you remove the side cover with force without removing the seat, the panel 2 (on the inside) may contact the air cleaner case and come off. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter-. Needle holder Jet needle Float chamber Float pin Float Needle valve Main jet. EC463000 REMOVAL POINTS EC463110 Throttle valve 1. NOTE: 9Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. 9Never use a wire. 2. Inspect: 9Main jet 1 9Pilot jet 2 9Power jet 3 Contamination. Verschmutzung Reinigen. Contaminazione Pulirlo. EC464701 Reed valve 1. Measure: 9Reed valve bending a Out of specification Replace.Danni Sostituirlo. IC464701 Soupape flexible Zungenventil Valvola a lamella 1. Be sure to use the set pin. If the set pin is not used, the power valve constituent parts will result in damage. EC474000 INSPECTION EC474101 Cylinder head 1. Remove: 9Carbon deposits Use a rounded scraper 1. NOTE: Take care to avoid damaging the spark plug threads. Avoid scratching the aluminum. 2. Inspect: 9Cylinder inner surface Score marks Repair or replace. Do not rebore the cylinder. Out of specification Replace.EC474502 Piston ring 1. Install: 9Piston ring Into the cylinder. Refer to “Cylinder” and “Piston”.http://www.risingstars.com.tr/wp-content/plugins/formcraft/file-upload/server/content/files/16273d150a5049---brk-4120b-smoke-alarm-manual.pdfCylinder mark Piston mark (color) A (red) B (orange) C (green) D (purple) NOTE: When you purchase a cylinder, you cannot des- ignate its size. Choose the piston that matches the above chart. Be sure to use the set pin. Measure at all four points.Zum Kupplungsdeckel. Verso la protezione della frizio- 11. EC4B4400 Shift shaft 1. EC4G3210 Oil seal NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as. EC4H4600 Bearing 1. Inspect: 9Bearing 1 Rotate inner race with a finger. EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111 Oil seal 1. EC4N3211 Crankcase 1. Remove: 9Crankcase (right) 1 Use the crankcase separating tool 2 and crankcase separating bolt 3. EC4N3401 Crankshaft bearing 1. EC4N4202 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. EC4N5282 Crankshaft 1. Note the position of each part. Pay particular attention to the location and direction of shift forks. NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adja- cent to the shift fork. NOTE: 9Apply the molybdenum disulfide oil on the shift fork grooves. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading. 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. Replace the piston seals and dust seals whenever a caliper is disassembled. NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. A Front B Rear 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 the brake hose to the caliper with the paint a a on the pipe facing the caliper and with the pipe contacting the caliper.www.highlandmetals.co.za/wp-content/plugins/formcraft/file-upload/server/content/files/16273d1934dcc5---brk-4120sb-smoke-alarm-manual.pdf 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. If it does, correct its twist. Refer to “BRAKE FLUID LEVEL INSPEC- TION”. 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. Take care not to scratch the inner tube. 2. Remove: 9Inner tube 1 Oil seal removal steps: a the inner tube just be- 9 Push in slowly fore it bottoms out and then pull it back quickly b. EC554400 Fork spring 1. Measure: 9Fork spring free length a Out of specification Replace. Fork spring free length: Standard 460 mm 455 mm (18.1 in) (17.9 in) EC554502. EC555000 ASSEMBLY AND INSTALLATION EC5551A1 Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: 9Damper rod 1 To inner tube 2. Install: 9Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level. If torqued too much, it may cause the front fork to malfunction. Tube guide 5-41. EC5B3200 Grip 1. If you make a mistake in the grip cap installation position, the brake lever may contact the grip cap, resulting in poor brake performance. Bloccare la parte della brida a 14. Das Klemmteil Nummernschildes plaque d’immatriculation au gui- della targa sul manubrio.EC563300 Bearing (lower) 1. Remove: 9Bearing (lower) 1 Use the floor chisel 2. Install the bearing in the ball races. Spin the bearings by hand. If not, adjust the steering by loosening the ring nut little by little. 10. Adjust: 9Front fork top end a Front fork top end (standard) a a: Zero mm (Zero in) 11.annassteen.com/ckfinder/userfiles/files/compact-php-manual.pdf EC574010 INSPECTION Wash the bearings, bushes, collars, and covers in a solvent.NOTE: 9Apply the molybdenum disulfide grease on the bearing when installing. 9Install the bearing by pressing it on the side hav- ing the manufacture's marks or numbers. Install: 9Cap 1 NOTE: Install the cap with its mark a facing forward. 13. To dispose of a damaged or worn-out shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5-60. Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear- ing is press fitted. No good Check each couplers and Repair or replace.Mauvais Magnetventilspule Changer. Nicht in Ordnung Erneuern oder Alle Stecker - und Kabelverbin- reparieren. Nicht in Ordnung Magnetventilspule Erneuern. Non funziona Controllare tutti gli accoppiatori e i Ripararlo o sostituirlo.Non funziona Controllare il funziona- Controllare l’elettrovalvola. Sostituirlo. mento dell’elettrovalvola. EC652040 SOLENOID VALVE OPERATION 1. Disconnect the solenoid valve coupler. 2. Connect 12V battery to the solenoid valve coupler. No good Check entire ignition Repair or replace.No good Check TPS. TPS coil Replace. In Ordnung Nicht in Ordnung TPS kontrollieren. TPS-Spule Erneuern. Controllare il collegamento dell’intero Non funziona Ripararlo o sostituirlo.Non funziona Controllare il TPS. EC692000 TPS COIL INSPECTION 1. Remove: 9Carburetor 9Mixing chamber top Refer to “CARBURETOR AND REED VALVE” section in the CHAPTER 4. 2. Refer to “IDLE SPEED ADJUSTMENT” sec- tion in the CHAPTER 3. Ausrichtmarkierungen a am TPS 11. Segnare le indicazioni a di posi- 11.Accord- ingly, if a mixture of air and fuel is too lean, abnormal combustion will occur, and engine seizure may result. In this case, step up the jet needle clip by one groove and move down the needle to lean out the mixture. Therefore, carburetor setting requires the change of the jet needle. 1. Therefore, carburetor setting requires the change of the jet needle. 1. The jet needle setting parts, having the same taper angle, are available in different straight portion diameters and in different taper starting positions. White smoke Unstable at low speeds Lower jet needle clip position. The front fork setting includes the following three factors: 1. Setting of air spring characteristics 9Change the fork oil level. Always adjust each front fork to the same setting. Rebound damping tends to become weaker, resulting in lack of a sense of con- tact with the road surface or in a vibrating handlebar. To set a stiff spring: 9Change the rebound damping. Die una sensazione di guida rigida. The rear suspension setting includes the follow- ing two factors: 1. Setting of spring preload 9Change the set length of the spring. Never use one whose overall length is greater than standard. In doing so, no representation of affiliation, association or the like is intended, unless otherwise stated. Moreover, we are in fact owners of intellectual property, property that is a valuable asset to our business. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. Dieses Modell entspricht fort-. Off-road use on public lands may also be illegal. Please check local regulations before riding. 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. 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, con-. Dar- faisant le plein.If there is any question you have regarding this manual or your machine, please consult your Yamaha deal- EC070001 F.I.M. MACHINE WEIGHTS: Weights of machines without fuel. The information has been complied to provide the mechanic with an easy to read, handy reference that contains com- prehensive 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.g., 9 Bearings. General information INSP Specifications Regular inspection and adjustments Engine Chassis Electrical Tuning CHAS ELEC Illustrated symbols 8 to r are used to identify the specifications appearing in the text. When washing the machine with high pres- sured water, cover the parts as follows. 9 Silencer exhaust port 9 Side cover air intake port 9 Water pump housing hole at the bottom. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. Bauteile zu verwenden.Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is posi- tioned opposite to the thrust 3 it receives. See the sectional view. 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. La forma e il numero categorico usati per l’utensile speciale sono diversi a seconda del paese, quindi vengono forniti due tipi. Continue pushing the “ENGINE STOP” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left handle- bar;. 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. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. 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. Mixing oil: Mixing ratio: Yamalube “2-R” 15:1 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “ENGINE STOP”. Tighten all such fasteners as required. 9 When any of the following parts have been replaced, they must be broken in. After cleaning machine thoroughly, prepare it for storage as fol- lows: 1. Drain the fuel tank, fuel lines, and the carbu- retor float bowl. 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. G Clamp the radiator breather 2 Clamp the frame at its locating tape. 3 CDI magneto lead Clamp it at the rear of the radia- hose, CDI magneto lead and 4 Neutral switch lead (except for tor fitting boss. B Pass the high tension cord to 3 High tension cord 4 CDI unit band the right of the radiator hose so 5 CDI unit that the high tension cord does 6 CDI unit lead not contact the radiator hose. B Pass the brake hose into the brake hose holders. C If the brake hose contacts the spring (rear shock absorber), correct its twist. B Pass the “ENGINE STOP” button lead in the middle 4 “ENGINE STOP”. Before using this machine, check the following points. EC321000 GENERAL INSPECTION AND MAINTENANCE Item Routine Page. Prima di usare questo veicolo, controllare i punti che seguono. IC321000 ISPEZIONE E MANUTENZIONE GENERALI Voce. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. If it splashes, wash it away with water. 1. Place a container under the engine. 2. 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. Throttle grip free play.Never run the engine without the air filter element in place;. NOTE: Squeeze out the excess oil. Element should be wet but not dripping. 5. Install: 9 Filter guide 1 NOTE: Align the projection a on filter guide with the hole b in air filter element. 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. 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. j. 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. NOTE: Replace the drive, driven sprockets and drive chain as a set.EC36U070 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: 9 Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth. Avoid over-tightening.Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter-. Needle holder Jet needle Float chamber Float pin. EC463000 REMOVAL POINTS EC463110 Throttle valve 1. NOTE: 9 Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. 9 Never use a wire. 2. Be sure to use the set pin. If the set pin is not used, the power valve constituent parts will result in damage. EC474000 INSPECTION EC474102 Cylinder head 1. Eliminate: 9 Carbon deposits Use a rounded scraper 1. EC474502 Piston ring 1. Install: 9 Piston ring Into the cylinder. Refer to “Cylinder” and “Piston”.Cylinder mark Piston mark (color) A (red) B (orange) C (green) D (purple) NOTE: When you purchase a cylinder, you cannot des- ignate its size. Choose the piston that matches the above chart. Measure at all four points.Zum Kupplungsdeckel. Verso la protezione della frizio- 11. EC4K4200 Bearing 1. EC4G3210 Oil seal NOTE:. EC4H4600 Bearing 1. Inspect: 9 Bearing 1 Rotate inner race with a finger.If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when removing the bolt. Do not use a hammer to drive out the crankshaft. NOTE: Install the bearing by pressing its outer race parallel. EC4N5102 Oil seal 1. Install: 9 Oil seal (left) 1 9 Oil seal (right) 2 NOTE: 9 Apply the lithium soap base grease on the oil. Note the position of each part. NOTE: 9 Apply the molybdenum disulfide oil on the shift fork grooves. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading. A Front B Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable contain- er under its end. Never attempt to pry out piston seals and dust seals. Install the brake hose so that its pipe por- tion a a directs as shown and lightly touch- es the projection b b on the master cylinder. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3. EC5A5911 Front brake hose 1. Install the brake hose so that its pipe por- tion a a directs as shown and lightly touch- es the projection b b on the master cylinder. If it does, correct its twist. Refer to “BRAKE FLUID LEVEL INSPEC- TION”. So it is recommended that the front fork be maintained at the dealers.