yamaha yzf-r15 service manual (english)

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2008 SERVICE MANUAL YZF-R15 20P-F8197-E0

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service manual for Yamaha R15 V1

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  • 2008

    SERVICE MANUAL

    YZF-R15

    20P-F8197-E0

  • YZF-R15

    SERVICE MANUAL

    Allrightsreserved.Any reproduction or unauthorized use

    withoutthewrittenpermissionof

    YAMAHA MOTOR INDIA SALES PVT. LTD.

    is expressly prohibited.

    NOTICEThis manual was produced by YMIS. primarily for use by YMIS dealers and their qualified mechanics. Itis not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who usesthis book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding ofmechanics and the techniques to repair these types of vehicles. Repair and maintenance workattempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.India Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications andsignificant changes in specifications or procedures will be forwarded to all authorized YMIS dealers andwill appear in future editions of this manual where applicable.

    Designs and specifications are subject to change without notice.

    Particularly important information is distinguished in this manual by the following.

    The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

    Failure to follow WARNING instructions could result in severe injury or death to thevehicle operator, a bystander or a person checking or repairing the vehicle.

    ACAUTION indicates special precautions that must be taken to avoid damage to thevehicle.

    ANOTE provides key information to make procedures easier or clearer.

    NOTE:

    IMPORTANT MANUAL INFORMATION

    NOTE:

    CAUTION:

    WARNING

  • YZF-R15

    SERVICE MANUAL

    Allrightsreserved.Any reproduction or unauthorized use

    withoutthewrittenpermissionof

    YAMAHA MOTOR INDIA SALES PVT. LTD.

    is expressly prohibited.

    NOTICEThis manual was produced by YMIS. primarily for use by YMIS dealers and their qualified mechanics. Itis not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who usesthis book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding ofmechanics and the techniques to repair these types of vehicles. Repair and maintenance workattempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.India Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications andsignificant changes in specifications or procedures will be forwarded to all authorized YMIS dealers andwill appear in future editions of this manual where applicable.

    Designs and specifications are subject to change without notice.

    Particularly important information is distinguished in this manual by the following.

    The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

    Failure to follow WARNING instructions could result in severe injury or death to thevehicle operator, a bystander or a person checking or repairing the vehicle.

    ACAUTION indicates special precautions that must be taken to avoid damage to thevehicle.

    ANOTE provides key information to make procedures easier or clearer.

    NOTE:

    IMPORTANT MANUAL INFORMATION

    NOTE:

    CAUTION:

    WARNING

  • HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laid outwith the individual steps in sequential order.

    The manual is divided into chapters and each chapter is divided into sections. The current section title1 is shown at the top of each page.

    Sub-section titles 2 appear in smaller print than the section title.

    To help identify parts and clarify procedure steps, there are exploded diagrams 3 at the start of eachremoval and disassembly section.

    Numbers 4 are given in the order of the jobs in the exploded diagram. A number indicates adisassembly step.

    Symbols 5 indicate parts to be lubricated or replaced. Refer to SYMBOLS.

    A job instruction chart 6 accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

    Jobs 7 requiring more information (such as special tools and technical data) are describedsequentially.

    1

    73

    4

    5

    62

    SYMBOLSThe following symbols are used in this manual foreasier understanding.

    NOTE:The following symbols are not relevant to everyvehicle.

    1. Serviceable with engine mounted2. Filling fluid3. Lubricant4. Special tool5. Tightening torque6. Wear limit, clearance7. Engine speed8. Electrical data9. Engine oil10. Gear oil11. Molybdenum disulfide oil12. Brake fluid13. Wheel bearing grease14. Lithium-soap-based grease15 Molybdenum disulfide grease16. Silicone grease17 Apply locking agent (LOCTITE).18 Replace the part with a new one.

    9 10

    11 12

    13 14

    15 16

    17 18

    LT New

    1 2 3

    4 5 6

    7 8

    ClutchHubHolderYSST-733

  • HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laid outwith the individual steps in sequential order.

    The manual is divided into chapters and each chapter is divided into sections. The current section title1 is shown at the top of each page.

    Sub-section titles 2 appear in smaller print than the section title.

    To help identify parts and clarify procedure steps, there are exploded diagrams 3 at the start of eachremoval and disassembly section.

    Numbers 4 are given in the order of the jobs in the exploded diagram. A number indicates adisassembly step.

    Symbols 5 indicate parts to be lubricated or replaced. Refer to SYMBOLS.

    A job instruction chart 6 accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

    Jobs 7 requiring more information (such as special tools and technical data) are describedsequentially.

    SYMBOLSThe following symbols are used in this manual foreasier understanding.

    NOTE:The following symbols are not relevant to everyvehicle.

    1. Serviceable with engine mounted2. Filling fluid3. Lubricant4. Special tool5. Tightening torque6. Wear limit, clearance7. Engine speed8. Electrical data9. Engine oil10. Gear oil11. Molybdenum disulfide oil12. Brake fluid13. Wheel bearing grease14. Lithium-soap-based grease15 Molybdenum disulfide grease16. Silicone grease17 Apply locking agent (LOCTITE).18 Replace the part with a new one.

    G

    M

    E

    B LS

    M

    9 10

    11 12

    13 14

    15 16

    17 18

    LT New

    BF

    S

    TR..

    1 2 3

    4 5 6

    7 8

    ClutchHubHolderYSST-733

  • TABLE OF CONTENTS

    GENERAL INFORMATION 1

    2

    3

    4

    5

    6

    7

    8

    9

    PERIODIC CHECKS ANDADJUSTMENTS

    SPECIFICATIONS

    CHASSIS

    ENGINE

    COOLING SYSTEM

    FUEL SYSTEM

    ELECTRICAL SYSTEM

    TROUBLESHOOTING

    IDENTIFICATION

    FEATURES

    IMPORTANT INFORMATION

    CHECKING THE CONNECTIONS

    SPECIAL TOOLS

    ............................................................................................1-1VEHICLE IDENTIFICATION NUMBER.......................................................1-1ENGINE SERIAL NUMBER .......................................................................1-1

    ......................................................................................................1-2OUTLINE OF THE FI SYSTEM...................................................................1-2FI SYSTEM.................................................................................................1-3

    ..........................................................................1-4PREPARATION FOR REMOVALAND DISASSEMBLY...............................1-5REPLACEMENT PARTS............................................................................1-5GASKETS, OIL SEALS AND O-RINGS ......................................................1-5LOCK WASHERS/PLATESAND COTTER PINS........................................1-5BEARINGS AND OIL SEALS......................................................................1-6CIRCLIPS...................................................................................................1-6

    ..................................................................1-7

    ............................................................................................1-8

    GENERAL INFORMATION

  • TABLE OF CONTENTS

    GENERAL INFORMATION 1

    2

    3

    4

    5

    6

    7

    8

    9

    PERIODIC CHECKS ANDADJUSTMENTS

    SPECIFICATIONS

    CHASSIS

    ENGINE

    COOLING SYSTEM

    FUEL SYSTEM

    ELECTRICAL SYSTEM

    TROUBLESHOOTING

    IDENTIFICATION

    FEATURES

    IMPORTANT INFORMATION

    CHECKING THE CONNECTIONS

    SPECIAL TOOLS

    ............................................................................................1-1VEHICLE IDENTIFICATION NUMBER.......................................................1-1ENGINE SERIAL NUMBER .......................................................................1-1

    ......................................................................................................1-2OUTLINE OF THE FI SYSTEM...................................................................1-2FI SYSTEM.................................................................................................1-3

    ..........................................................................1-4PREPARATION FOR REMOVALAND DISASSEMBLY...............................1-5REPLACEMENT PARTS............................................................................1-5GASKETS, OIL SEALS AND O-RINGS ......................................................1-5LOCK WASHERS/PLATESAND COTTER PINS........................................1-5BEARINGS AND OIL SEALS......................................................................1-6CIRCLIPS...................................................................................................1-6

    ..................................................................1-7

    ............................................................................................1-8

    GENERAL INFORMATION

  • IDENTIFICATION

    IDENTIFICATION

    VEHICLE IDENTIFICATION NUMBER (FRAMENO.)

    ENGINE SERIAL NUMBER

    NOTE:

    The vehicle identification number 1 is stampedinto the frame.

    The engine serial number 1 is stamped into thecrankcase.

    Designs and specifications are subject to changewithout notice.

    1

    FEATURES

    OUTLINE OF THE FI SYSTEMThe main function of a fuel supply system is to provide fuel to the combustion chamber at the optimumair-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In theconventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustionchamber is created by the volume of the intake air and the fuel that is metered by the jet used in therespective carburetor.Despite the same volume of intake air, the fuel volume requirement varies by the engine operatingconditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meterthe fuel through the use of jets have been provided with various auxiliary devices, so that an optimumairfuel ratio can be achieved to accommodate the constant changes in the operating conditions of theengine.As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, itbecomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. Toaccommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, inplace of the conventional carburetor system. This system can achieve an optimum air-fuel ratio requiredby the engine at all times by using a microprocessor that regulates the fuel injection volume according tothe engine operating conditions detected by various sensors. The adoption of the FI system has resultedin a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaustemissions.

    1. Engine trouble warning light2. Spark plug3. Ignition coil4. Fuel pump5. FID (fast idle solenoid)6. Throttle body sensor assembly (consisting of

    throttle position sensor, intake air pressuresensor, intake air temperature sensor)

    7. ECU (engine control unit)8. Lean angle sensor9. Crankshaft position sensor10.Fuel injector11.Coolant temperature sensor

    1-1 1-2

    1

    xxxxxxx

  • FEATURES

    IDENTIFICATION

    VEHICLE IDENTIFICATION NUMBER (FRAMENO.)

    ENGINE SERIAL NUMBER

    NOTE:

    The vehicle identification number 1 is stampedinto the frame.

    The engine serial number 1 is stamped into thecrankcase.

    Designs and specifications are subject to changewithout notice.

    FEATURES

    OUTLINE OF THE FI SYSTEMThe main function of a fuel supply system is to provide fuel to the combustion chamber at the optimumair-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In theconventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustionchamber is created by the volume of the intake air and the fuel that is metered by the jet used in therespective carburetor.Despite the same volume of intake air, the fuel volume requirement varies by the engine operatingconditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meterthe fuel through the use of jets have been provided with various auxiliary devices, so that an optimumairfuel ratio can be achieved to accommodate the constant changes in the operating conditions of theengine.As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, itbecomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. Toaccommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, inplace of the conventional carburetor system. This system can achieve an optimum air-fuel ratio requiredby the engine at all times by using a microprocessor that regulates the fuel injection volume according tothe engine operating conditions detected by various sensors. The adoption of the FI system has resultedin a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaustemissions.

    1. Engine trouble warning light2. Spark plug3. Ignition coil4. Fuel pump5. FID (fast idle solenoid)6. Throttle body sensor assembly (consisting of

    throttle position sensor, intake air pressuresensor, intake air temperature sensor)

    7. ECU (engine control unit)8. Lean angle sensor9. Crankshaft position sensor10.Fuel injector11.Coolant temperature sensor

    1-1 1-2

    1

    xxxxxxx

    91011

    1 2 3 4 5,6 7 8

  • FEATURESFI SYSTEMThe fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuelpressure that is applied to the fuel injector at only 250 kPa (2.50 kg/cm, 35.6 psi). Accordingly, when theenergizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to beinjected into the intake manifold only during the time the passage remains open. Therefore, the longer thelength of time the fuel injector is energized (injection duration), the greater the volume of fuel that issupplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), thelesser the volume of fuel that is supplied.

    The injection duration and the injection timing are controlled by the ECU. Signals that are input from thethrottle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperaturesensor, lean angle sensor and coolant temperature sensor enable the ECU to determine the injectionduration. The injection timing is determined through the signals from the crankshaft position sensor. As aresult, the volume of fuel that is required by the engine can be supplied at all times in accordance with thedriving conditions.

    1. Fuel pump2. Fuel injector3. Ignition coil4. Coolant temperature sensor5. ECU (engine control unit)6. Lean angle sensor7. Crankshaft position sensor8. FID (fast idle solenoid)9. Air filter case10. Throttle body11. Throttle body sensor assembly12. Intake air temperature sensor13. Throttle position sensor

    14. IntakeairpressuresensorA. FuelsystemB. AirsystemC. Controlsystem

    12

    1410

    9

    1

    2

    3 4

    65

    7

    8

    1113

    The multi-function display is equipped with thefollowing: a speedometer (which shows the riding speed) an odometer (which shows the total distance

    traveled) two tripmeters (which show the distance

    traveled since they were last set to zero) a fuel reserve tripmeter (which shows the

    distance traveled since the fuel level warninglight came on)

    a fuel meter

    1.Multi-functiondisplay2. RESET/SELECT button

    Odometer and tripmeter modes

    ( )

    /

    1 2

    :

    1 2

    1.

    ,

    -

    ,

    . ,

    /

    :

    - 1 2 -

    A brief push less than one second on the

    RESET SELECT button switches the display

    between the odometer mode ODO and the

    tripmeter modes TRIP and TRIP in the

    following order

    ODO TRIP TRIP ODO

    When approximately 9 L of fuel remains in the

    fuel tank the odometer display will automatically

    change to the fuel reserve tripmeter mode F

    TRIP and start counting the distance traveled

    from that point and the last segment of the fuel

    meter will start flashing In that case pushing the

    RESET SELECT button switches the display

    between the various tripmeter and odometer

    modes in the following order

    F TRIP TRIP TRIP ODO F TRIP

    1-3 1-4

    Tripmeter will reset itself automatically and thedisplay will return to the prior mode after refuelingand traveling 5 km (3 mi).

    The fuel meter indicates the amount of fuel in thefuel tank. The display segments of the fuel meterdisappear towards E (Empty) as the fuel leveldecreases. When the last fuel meter segmentstarts flashing, refuel as soon as possible.

    1. Fuel meter

  • FEATURESFI SYSTEMThe fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuelpressure that is applied to the fuel injector at only 250 kPa (2.50 kg/cm, 35.6 psi). Accordingly, when theenergizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to beinjected into the intake manifold only during the time the passage remains open. Therefore, the longer thelength of time the fuel injector is energized (injection duration), the greater the volume of fuel that issupplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), thelesser the volume of fuel that is supplied.

    The injection duration and the injection timing are controlled by the ECU. Signals that are input from thethrottle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperaturesensor, lean angle sensor and coolant temperature sensor enable the ECU to determine the injectionduration. The injection timing is determined through the signals from the crankshaft position sensor. As aresult, the volume of fuel that is required by the engine can be supplied at all times in accordance with thedriving conditions.

    1. Fuel pump2. Fuel injector3. Ignition coil4. Coolant temperature sensor5. ECU (engine control unit)6. Lean angle sensor7. Crankshaft position sensor8. FID (fast idle solenoid)9. Air filter case10. Throttle body11. Throttle body sensor assembly12. Intake air temperature sensor13. Throttle position sensor

    14. IntakeairpressuresensorA. FuelsystemB. AirsystemC. Controlsystem

    MULTI-FUNCTION DISPLAY

    The multi-function display is equipped with thefollowing: a speedometer (which shows the riding speed) an odometer (which shows the total distance

    traveled) two tripmeters (which show the distance

    traveled since they were last set to zero) a fuel reserve tripmeter (which shows the

    distance traveled since the fuel level warninglight came on)

    a fuel meter

    1.Multi-functiondisplay2. RESET/SELECT button

    Odometer and tripmeter modes

    ( )

    /

    1 2

    :

    1 2

    1.

    ,

    -

    ,

    . ,

    /

    :

    - 1 2 -

    A brief push less than one second on the

    RESET SELECT button switches the display

    between the odometer mode ODO and the

    tripmeter modes TRIP and TRIP in the

    following order

    ODO TRIP TRIP ODO

    When approximately 9 L of fuel remains in the

    fuel tank the odometer display will automatically

    change to the fuel reserve tripmeter mode F

    TRIP and start counting the distance traveled

    from that point and the last segment of the fuel

    meter will start flashing In that case pushing the

    RESET SELECT button switches the display

    between the various tripmeter and odometer

    modes in the following order

    F TRIP TRIP TRIP ODO F TRIP

    1-3 1-4

    Tripmeter will reset itself automatically and thedisplay will return to the prior mode after refuelingand traveling 5 km (3 mi).

    The fuel meter indicates the amount of fuel in thefuel tank. The display segments of the fuel meterdisappear towards E (Empty) as the fuel leveldecreases. When the last fuel meter segmentstarts flashing, refuel as soon as possible.

    Fuel meter

    1. Fuel meter

    2

    1

    1

  • 1-5 1-6

    IMPORTANTINFORMATION IMPORTANTINFORMATION

    IMPORTANT INFORMATION

    PREPARATION FOR REMOVALANDDISASSEMBLY1. Before removal and disassembly, remove all

    dirt, mud, dust and foreign material.

    2. Use only the proper tools and cleaningequipment.Refer to SPECIALTOOLS on page 1-8.

    3. When disassembling, always keep matedparts together. This includes gears, cylinders,pistons and other parts that have been matedthrough normal wear. Mated parts must alwaysbe reused or replaced as an assembly.

    4. During disassembly, clean all of the parts andplace them in trays in the order of disassembly.This will speed up assembly and allow for thecorrect installation of all parts.

    5. Keep all parts away from any source of fire.

    REPLACEMENT PARTSUse only genuine Yamaha parts for allreplacements. Use oil and grease recommendedby Yamaha for all lubrication jobs. Other brandsmay be similar in function and appearance, butinferior in quality.

    GASKETS, OIL SEALSAND O-RINGS1. When overhauling the engine, replace all

    gaskets, seals and O-rings. All gasketsurfaces, oil seal lips and O-rings must becleaned.

    2. During reassembly, properly oil all matingparts and bearings and lubricate the oilseallips with grease.

    LOCK WASHERS/PLATESAND COTTERPINSAfter removal, replace all lock washers/plates 1and cotter pins. After the bolt or nut has beentightened to specification, bend the lock tabsalong a flat of the bolt or nut.

    BEARINGSAND OIL SEALSInstall bearings and oil seals so that themanufacturers marks or numbers are visible.When installing oil seals 1, lubricate the oil seallips with a light coat of lithium-soap-basedgrease. Oil bearings liberally when installing, ifappropriate.

    Do not spin the bearing with compressed airbecause this will damage the bearingsurfaces.

    CIRCLIPSBefore reassembly, check all circlips carefullyand replace damaged or distorted circlips.Always replace piston pin clips after one use.When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust3 that the circlip receives.

    CAUTION:

  • 1-5 1-6

    IMPORTANTINFORMATION IMPORTANTINFORMATION

    IMPORTANT INFORMATION

    PREPARATION FOR REMOVALANDDISASSEMBLY1. Before removal and disassembly, remove all

    dirt, mud, dust and foreign material.

    2. Use only the proper tools and cleaningequipment.Refer to SPECIALTOOLS on page 1-8.

    3. When disassembling, always keep matedparts together. This includes gears, cylinders,pistons and other parts that have been matedthrough normal wear. Mated parts must alwaysbe reused or replaced as an assembly.

    4. During disassembly, clean all of the parts andplace them in trays in the order of disassembly.This will speed up assembly and allow for thecorrect installation of all parts.

    5. Keep all parts away from any source of fire.

    REPLACEMENT PARTSUse only genuine Yamaha parts for allreplacements. Use oil and grease recommendedby Yamaha for all lubrication jobs. Other brandsmay be similar in function and appearance, butinferior in quality.

    GASKETS, OIL SEALSAND O-RINGS1. When overhauling the engine, replace all

    gaskets, seals and O-rings. All gasketsurfaces, oil seal lips and O-rings must becleaned.

    2. During reassembly, properly oil all matingparts and bearings and lubricate the oilseallips with grease.

    LOCK WASHERS/PLATESAND COTTERPINSAfter removal, replace all lock washers/plates 1and cotter pins. After the bolt or nut has beentightened to specification, bend the lock tabsalong a flat of the bolt or nut.

    BEARINGSAND OIL SEALSInstall bearings and oil seals so that themanufacturers marks or numbers are visible.When installing oil seals 1, lubricate the oil seallips with a light coat of lithium-soap-basedgrease. Oil bearings liberally when installing, ifappropriate.

    Do not spin the bearing with compressed airbecause this will damage the bearingsurfaces.

    CIRCLIPSBefore reassembly, check all circlips carefullyand replace damaged or distorted circlips.Always replace piston pin clips after one use.When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust3 that the circlip receives.

    CAUTION:

  • 1-7 1-8

    CHECKINGTHECONNECTIONS SPECIAL TOOLS

    CHECKING THE CONNECTIONSCheck the leads couplers and connectors for

    stains rust moisture etc

    Disconnect

    Lead Coupler Connector

    Check

    Moisture Dry with an air blower

    Ruststains Connect and disconnect several

    times

    , ,

    , , , .

    1. :

    2. :

    .

    /

    .

    Lead Coupler Connector

    3. Check: All connections

    Loose connection Connect properly.

    If the pin 1 on the terminal is flattened, bend it up.

    NOTE:

    4. Connect: Lead Coupler Connector

    Make sure all connections are tight.

    5. Check: Continuity

    (with the multimeter)

    NOTE:

    NOTE: If there is no continuity, clean the terminals. When checking the wire harness, perform

    steps (1) to (3). As a quick remedy, use a contact revitalizer

    available at most part stores.

    SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use only theappropriate special tools as this will help prevent damage caused by the use of inappropriate tools orimprovised techniques.

    Tool name/Tool No. Illustration

    Tappet adjusting socket

    Tappet screw holder

    YSST-706

    Thistoolisusedtoloosenandtightentappetadjustingnut.

    Thistoolisusedtoadjustthevalveclearancebytappetadjustingscrew

    YSST-706A

    Feeler gaugeYSST-715

    Thistoolisusedtoadjustthevalveclearanceinanengine

    Valve spring compressor

    YSST-603

    ThistoolisusedtoremoveandinstallValve&SpringAssemblies.

    Magneto holder

    YSST-701

    Magneto puller

    YSST-702

    ThistoolisusedtoholdthemagnetowhenremovingorinstallingthemagnetosecuringNutandPrimaryDriveGearNut

    Thistoolisusedtoremovethemagnetowiththehelpofmagnetoholder.

  • 1-7 1-8

    CHECKINGTHECONNECTIONS SPECIAL TOOLS

    CHECKING THE CONNECTIONSCheck the leads couplers and connectors for

    stains rust moisture etc

    Disconnect

    Lead Coupler Connector

    Check

    Moisture Dry with an air blower

    Ruststains Connect and disconnect several

    times

    , ,

    , , , .

    1. :

    2. :

    .

    /

    .

    Lead Coupler Connector

    3. Check: All connections

    Loose connection Connect properly.

    If the pin 1 on the terminal is flattened, bend it up.

    NOTE:

    4. Connect: Lead Coupler Connector

    Make sure all connections are tight.

    5. Check: Continuity

    (with the multimeter)

    NOTE:

    NOTE: If there is no continuity, clean the terminals. When checking the wire harness, perform

    steps (1) to (3). As a quick remedy, use a contact revitalizer

    available at most part stores.

    SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use only theappropriate special tools as this will help prevent damage caused by the use of inappropriate tools orimprovised techniques.

    Tool name/Tool No. Illustration

    Tappet adjusting socket

    Tappet screw holder

    YSST-706

    Thistoolisusedtoloosenandtightentappetadjustingnut.

    Thistoolisusedtoadjustthevalveclearancebytappetadjustingscrew

    YSST-706A

    Feeler gaugeYSST-715

    Thistoolisusedtoadjustthevalveclearanceinanengine

    Valve spring compressor

    YSST-603

    ThistoolisusedtoremoveandinstallValve&SpringAssemblies.

    Magneto holder

    YSST-701

    Magneto puller

    YSST-702

    ThistoolisusedtoholdthemagnetowhenremovingorinstallingthemagnetosecuringNutandPrimaryDriveGearNut

    Thistoolisusedtoremovethemagnetowiththehelpofmagnetoholder.

  • 1-9 1-10

    SPECIAL TOOLSSPECIAL TOOLS

    Tool name/Tool No. Illustration

    Clutch hub holderYSST-733

    YSST-265

    Crankshaft removing tool

    ThistoolisusedtoholdtheClutchHubwhileremovingorinstallingClutchMainShaftNut.

    ThistoolisusedtoremovetheCrankShaftfromtheCrankCase.

    CrankShaftInstalling ToolwithSpacer(a) YSST-266(b) YSST-267

    ThesetoolsareusedforinstallationofCrankShaft.

    (a) (b)

    Tool name/Tool No. Illustration

    Timinglight

    Compression gauge

    Thisinstrumentisusedtoresettheignitiontiming.

    Thisinstrumentisusedtomeasuretheenginecompression.

    FI diagnostic tool

    Thisinstrumentisusedtodiagnosetheelectricalfaultsinfuelinjectionsystem

    ScraperYSST-612

    ThistoolisusedforscrapingthesealentfromCrankcasejoiningsurface.

    Radiator cap tester

    Radiator cap tester adapter

    Fuel Pressure gauge

    Vacuum/pressure pump gauge set

    Thisinstrumentisusedtomeasurethefuelpressure.

    Thisinstrumentisusedtotesttheradiatorcapfunctionality.

    Thisadapterisusedtoconnecttheradiatorcaptesterwithradiatorcapforradiatorcaptesting.

    Thisinstrumentisusedtoofferthevacuumtoairinductionsystemforchecking.

    Steering nut wrenchYSST-721

    Thistoolisusedtoloosenandtightenthesteeringnut.

    Thistoolisusedtoholdthe TFFplungerforlooseningandtighteningofHexSocketHeadBolt

    T-handle

    YSST-713

    Thistoolassiststoinstallthe TFFOilSeal.

    TFF Oil Seal Installation ToolYSST-775

  • 1-9 1-10

    SPECIAL TOOLSSPECIAL TOOLS

    Tool name/Tool No. Illustration

    Clutch hub holderYSST-733

    YSST-265

    Crankshaft removing tool

    ThistoolisusedtoholdtheClutchHubwhileremovingorinstallingClutchMainShaftNut.

    ThistoolisusedtoremovetheCrankShaftfromtheCrankCase.

    CrankShaftInstalling ToolwithSpacer(a) YSST-266(b) YSST-267

    ThesetoolsareusedforinstallationofCrankShaft.

    (a) (b)

    Tool name/Tool No. Illustration

    Timinglight

    Compression gauge

    Thisinstrumentisusedtoresettheignitiontiming.

    Thisinstrumentisusedtomeasuretheenginecompression.

    FI diagnostic tool

    Thisinstrumentisusedtodiagnosetheelectricalfaultsinfuelinjectionsystem

    ScraperYSST-612

    ThistoolisusedforscrapingthesealentfromCrankcasejoiningsurface.

    Radiator cap tester

    Radiator cap tester adapter

    Fuel Pressure gauge

    Vacuum/pressure pump gauge set

    Thisinstrumentisusedtomeasurethefuelpressure.

    Thisinstrumentisusedtotesttheradiatorcapfunctionality.

    Thisadapterisusedtoconnecttheradiatorcaptesterwithradiatorcapforradiatorcaptesting.

    Thisinstrumentisusedtoofferthevacuumtoairinductionsystemforchecking.

    Steering nut wrenchYSST-721

    Thistoolisusedtoloosenandtightenthesteeringnut.

    Thistoolisusedtoholdthe TFFplungerforlooseningandtighteningofHexSocketHeadBolt

    T-handle

    YSST-713

    Thistoolassiststoinstallthe TFFOilSeal.

    TFF Oil Seal Installation ToolYSST-775

  • 1-11

    SPECIAL TOOLS

    Mechanical seal/bearing InstallerYSST-722

    Tool name/Tool No. IllustrationReference

    Ignition checker

    Multimeter

    Thistoolisusedtoinstallthesealandbearinginwaterassy.pump

    Thisinstrumentisusedtochecktheeffficiencyofignitionatsparkplug.

    Thisinstrumentisusedtochecktheelectricalcircuitsorcomponents.

    Yamaha bond No. 1215

    Thisadhesiveisusedonmatingsurfaceswhileassem-blingCrankcase#1and#2.

    LOCTITEThreeBond1322

    Thisadhesiveisusedfortighteningof TorxScrew.

  • GENERAL SPECIFICATIONS

    ENGINE SPECIFICATIONS

    CHASSIS SPECIFICATIONS

    ELECTRICAL SPECIFICATIONS

    TIGHTENING TORQUES

    LUBRICATION POINTS AND LUBRICANT TYPES

    LUBRICATION SYSTEM CHART AND DIAGRAMS

    COOLING SYSTEM DIAGRAMS

    CABLE ROUTING

    ..........................................................................2-1

    .............................................................................2-2

    ............................................................................2-9

    ..................................................................2-12

    ...............................................................................2-15GENERAL TIGHTENING TORQUE SPECIFICATIONS..........................2-15ENGINE TIGHTENING TORQUES..........................................................2-16CHASSIS TIGHTENING TORQUES........................................................2-20

    .......................................2-22ENGINE...................................................................................................2-22CHASSIS.................................................................................................2-24

    .......................................2-25ENGINE OIL LUBRICATION CHART ......................................................2-25LUBRICATION DIAGRAMS ....................................................................2-27

    ....................................................................2-31

    ..........................................................................................2-33

    SPECIFICATIONS

  • 2-1

    GENERAL SPECIFICATIONS

    GENERAL SPECIFICATIONS

    Model

    Dimensions

    Weight

    Model 20P1

    Overalllength 1995mmOverallwidth 670mmOverallheight 1070mmSeatheight 790mmWheelbase 1290mmGroundclearance 160mmMinimumturningradius 2500mm

    Withoilandfuel 131kgMaximumload 199kg

    2-2

    ENGINE SPECIFICATIONS

    Engine

    Fuel

    Engine oil

    Oil filter

    Oil pump

    Cooling system

    Engine type Liquid cooled stroke SOHC

    Displacement cm

    Cylinder arrangement Forward-inclined single cylinderBore x stroke 57.0 x 58.7 mm

    Compression ratio

    Compression pressure 5Psi 3.866 kgfcm )

    Starting system Electric starter

    Recommended fuel Regular unleaded gasoline only

    Fuel tank capacity L

    Lubrication system Wet sump

    Type SAE W

    Recommended engine oil grade YAMALUBE (Grade-SG)Engine oil quantity

    Total amount L

    Without oil filter element replacement L

    With oil filter element replacement L

    Oil filter type Paper

    Oil pump type Gear pump

    Inner rotor to outer rotor tip clearance Less than mm

    Limit mm

    Outer rotor to oil pump housing clearance mm

    Limit mm

    Oil pump housing to inner and outer rotor

    clearance mm

    Limit mm

    Rotor thickness mm

    Relief valve operating pressure kPa psi kgfcm )

    Radiator capacity including all routes 59L

    Coolant reservoir capacity

    up to the maximum level

    mark L

    Radiator cap opening pressure 107.9-137.3 kPa

    Valve relief pressure kPa

    ThermostatManufacturer NIPPON THERMOSTAT

    4- ,

    149.8

    10.40 :1

    5 ( /

    12.0

    20 40

    1.15

    0.95

    1.00

    - - - - - 0.15

    0.23

    - - - - - 0.13 0.18

    0.25

    - - - - - - -

    0.06 0.11

    0.18

    9.95 9.98

    39.2 78.4 (5.7 11.4 ) (0.39 0.78 /

    ( ) 0.

    (

    ) 0.25

    4.9

    2

    2

  • 2-1

    GENERAL SPECIFICATIONS

    GENERAL SPECIFICATIONS

    Model

    Dimensions

    Weight

    Model 20P1

    Overalllength 1995mmOverallwidth 670mmOverallheight 1070mmSeatheight 790mmWheelbase 1290mmGroundclearance 160mmMinimumturningradius 2500mm

    Withoilandfuel 131kgMaximumload 199kg

    2-2

    ENGINE SPECIFICATIONS

    ENGINE SPECIFICATIONS

    Engine

    Fuel

    Engine oil

    Oil filter

    Oil pump

    Cooling system

    Engine type Liquid cooled stroke SOHC

    Displacement cm

    Cylinder arrangement Forward-inclined single cylinderBore x stroke 57.0 x 58.7 mm

    Compression ratio

    Compression pressure 5Psi 3.866 kgfcm )

    Starting system Electric starter

    Recommended fuel Regular unleaded gasoline only

    Fuel tank capacity L

    Lubrication system Wet sump

    Type SAE W

    Recommended engine oil grade YAMALUBE (Grade-SG)Engine oil quantity

    Total amount L

    Without oil filter element replacement L

    With oil filter element replacement L

    Oil filter type Paper

    Oil pump type Gear pump

    Inner rotor to outer rotor tip clearance Less than mm

    Limit mm

    Outer rotor to oil pump housing clearance mm

    Limit mm

    Oil pump housing to inner and outer rotor

    clearance mm

    Limit mm

    Rotor thickness mm

    Relief valve operating pressure kPa psi kgfcm )

    Radiator capacity including all routes 59L

    Coolant reservoir capacity

    up to the maximum level

    mark L

    Radiator cap opening pressure 107.9-137.3 kPa

    Valve relief pressure kPa

    ThermostatManufacturer NIPPON THERMOSTAT

    4- ,

    149.8

    10.40 :1

    5 ( /

    12.0

    20 40

    1.15

    0.95

    1.00

    - - - - - 0.15

    0.23

    - - - - - 0.13 0.18

    0.25

    - - - - - - -

    0.06 0.11

    0.18

    9.95 9.98

    39.2 78.4 (5.7 11.4 ) (0.39 0.78 /

    ( ) 0.

    (

    ) 0.25

    4.9

    2

    2

  • 2-3

    ENGINE SPECIFICATIONS

    Valve opening temperature 80.583.5 CValve full open temperature 95.0 CValve lift (full open) 3.0 mm

    Radiator coreWidth 198.0 mmHeight 128.0 mmDepth 24.0 mm

    Water pumpWater pump type Single suction centrifugal pumpReduction ratio (0.500)

    Manufacturer/model NGK/CR8EManufacturer/model DENSO/U24ESR-NSpark plug gap 0.70.8 mm

    Volume 9.9010.50 cmWarpage limit 0.03 mm

    Drive system Chain drive (left)Camshaft lobe dimensions

    IntakeA 25.177 0.05 mmLimit 25.027 mmIntake B 30.275 0.05 mmLimit 30.125 mmExhaustA 25.115 0.05 mmLimit 24.965 mmExhaust B 30.282 0.05 mmLimit 30.132 mm

    Camshaft runout limit 0.03 mm

    Spark plug (s)

    Cylinder head

    Camshaft

    B

    A

    2-4

    Timing chain

    Rocker arm/rocker arm shaft

    Valve, valve seat, valve guide

    Model/number of links SILENT CHAIN/96Tensioning system Automatic

    Rocker arm inside diameter 9.98510.000 mmLimit 10.030 mmRocker arm shaft outside diameter 9.9669.976 mmLimit 9.950 mmRocker-arm-to-rocker-arm-shaft clearance 0.0090.034 mmLimit 0.08 mm

    Valve clearance (cold)Intake 0.100.14 mmExhaust 0.200.24 mm

    Valve dimensionsValve head diameterA(intake) 19.4019.60 mmValve head diameterA(exhaust) 16.9017.10 mm

    Valve face width B (intake) 1.5382.138 mmValve face width B (exhaust) 1.5382.138 mm

    Valve seat width C (intake) 0.901.10 mmValve seat width C (exhaust) 0.901.10 mm

    Valve margin thickness D (intake) 0.500.90 mmValve margin thickness D (exhaust) 0.500.90 mm

    Valve stem diameter (intake) 4.4754.490 mmLimit 4.450 mmValve stem diameter (exhaust) 4.4604.475 mmLimit 4.435 mmValve guide inside diameter (intake) 3.9504.050 mmValve guide inside diameter (exhaust) mmValve-stem-to-valve-guide clearance (intake) 0.0100.037 mm

    3.9504.050

  • 2-3

    Valve opening temperature 80.583.5 CValve full open temperature 95.0 CValve lift (full open) 3.0 mm

    Radiator coreWidth 198.0 mmHeight 128.0 mmDepth 24.0 mm

    Water pumpWater pump type Single suction centrifugal pumpReduction ratio (0.500)

    Manufacturer/model NGK/CR8EManufacturer/model DENSO/U24ESR-NSpark plug gap 0.70.8 mm

    Volume 9.9010.50 cmWarpage limit 0.03 mm

    Drive system Chain drive (left)Camshaft lobe dimensions

    IntakeA 25.177 0.05 mmLimit 25.027 mmIntake B 30.275 0.05 mmLimit 30.125 mmExhaustA 25.115 0.05 mmLimit 24.965 mmExhaust B 30.282 0.05 mmLimit 30.132 mm

    Camshaft runout limit 0.03 mm

    Spark plug (s)

    Cylinder head

    Camshaft

    2-4

    ENGINE SPECIFICATIONS

    Timing chain

    Rocker arm/rocker arm shaft

    Valve, valve seat, valve guide

    Model/number of links SILENT CHAIN/96Tensioning system Automatic

    Rocker arm inside diameter 9.98510.000 mmLimit 10.030 mmRocker arm shaft outside diameter 9.9669.976 mmLimit 9.950 mmRocker-arm-to-rocker-arm-shaft clearance 0.0090.034 mmLimit 0.08 mm

    Valve clearance (cold)Intake 0.100.14 mmExhaust 0.200.24 mm

    Valve dimensionsValve head diameterA(intake) 19.4019.60 mmValve head diameterA(exhaust) 16.9017.10 mm

    Valve face width B (intake) 1.5382.138 mmValve face width B (exhaust) 1.5382.138 mm

    Valve seat width C (intake) 0.901.10 mmValve seat width C (exhaust) 0.901.10 mm

    Valve margin thickness D (intake) 0.500.90 mmValve margin thickness D (exhaust) 0.500.90 mm

    Valve stem diameter (intake) 4.4754.490 mmLimit 4.450 mmValve stem diameter (exhaust) 4.4604.475 mmLimit 4.435 mmValve guide inside diameter (intake) 3.9504.050 mmValve guide inside diameter (exhaust) mmValve-stem-to-valve-guide clearance (intake) 0.0100.037 mm

    3.9504.050

    A

    B

    C

    D

  • 2-5

    ENGINE SPECIFICATIONS

    Limit 0.080 mmValve-stem-to-valve-guide clearance (exhaust) 0.0250.052 mmLimit 0.100 mmValve stem runout 0.010 mm

    Free length (intake) 41.71 mmLimit 39.62 mmFree length (exhaust) 41.71 mmLimit 39.62 mmInstalled length (intake) 35.30 mmInstalled length (exhaust) 35.30 mmSpring rate K1 (intake) 23.54 N/mmSpring rate K2 (intake) 36.58 N/mmSpring rate K1 (exhaust) 23.54 N/mmSpring rate K2 (exhaust) 36.58 N/mmInstalled compression spring force (intake) 140162 NInstalled compression spring force (exhaust) 140162 NSpring tilt (intake) 2.5/1.8 mmSpring tilt (exhaust) 2.5/1.8 mm

    Winding direction (intake) ClockwiseWinding direction (exhaust) Clockwise

    Bore 56.98557.010 mmTaper limit 0.05 mmOut of round limit 0.05 mm

    Piston-to-cylinder clearance 0.0200.045 mmLimit 0.15 mmDiameter D 56.96556.990 mm

    Valve spring

    Cylinder

    Piston

    Height H mm

    Offset mm

    Offset direction Intake side

    Piston pin bore inside diameter mm

    Limit mm

    Piston pin outside diameter mm

    Limit mm

    Piston pin to piston pin bore clearance mm

    Limit mm

    Top ringRing type Barrel

    Dimensions B x T) 0.80 x 2.10 mm

    End gap installed mm

    Limit mm

    Ring side clearance mm

    Limit mm

    nd ring

    Ring type Taper

    Dimensions B x T) 0.80 x 2.00 mm

    End gap installed mm

    Limit mm

    Ring side clearance mm

    Limit mm

    Oil ring

    Dimensions B x T) 1.50 x 1.52 mm

    End gap installed mm

    Ring side clearance mm

    5.0

    0.25

    14.002 14.013

    14.043

    13.995 14.000

    13.975

    - - - - - 0.002 0.018

    0.068

    (

    ( ) 0.10 0.25

    0.40

    0.030 0.065

    0.100

    2

    (

    ( ) 0.10 0.25

    0.40

    0.020 0.055

    0.100

    (

    ( ) 0.20 0.70

    0.040 0.160

    Piston ring

    2-6

  • 2-5

    Limit 0.080 mmValve-stem-to-valve-guide clearance (exhaust) 0.0250.052 mmLimit 0.100 mmValve stem runout 0.010 mm

    Free length (intake) 41.71 mmLimit 39.62 mmFree length (exhaust) 41.71 mmLimit 39.62 mmInstalled length (intake) 35.30 mmInstalled length (exhaust) 35.30 mmSpring rate K1 (intake) 23.54 N/mmSpring rate K2 (intake) 36.58 N/mmSpring rate K1 (exhaust) 23.54 N/mmSpring rate K2 (exhaust) 36.58 N/mmInstalled compression spring force (intake) 140162 NInstalled compression spring force (exhaust) 140162 NSpring tilt (intake) 2.5/1.8 mmSpring tilt (exhaust) 2.5/1.8 mm

    Winding direction (intake) ClockwiseWinding direction (exhaust) Clockwise

    Bore 56.98557.010 mmTaper limit 0.05 mmOut of round limit 0.05 mm

    Piston-to-cylinder clearance 0.0200.045 mmLimit 0.15 mmDiameter D 56.96556.990 mm

    Valve spring

    Cylinder

    Piston

    Height H mm

    Offset mm

    Offset direction Intake side

    Piston pin bore inside diameter mm

    Limit mm

    Piston pin outside diameter mm

    Limit mm

    Piston pin to piston pin bore clearance mm

    Limit mm

    Top ringRing type Barrel

    Dimensions B x T) 0.80 x 2.10 mm

    End gap installed mm

    Limit mm

    Ring side clearance mm

    Limit mm

    nd ring

    Ring type Taper

    Dimensions B x T) 0.80 x 2.00 mm

    End gap installed mm

    Limit mm

    Ring side clearance mm

    Limit mm

    Oil ring

    Dimensions B x T) 1.50 x 1.52 mm

    End gap installed mm

    Ring side clearance mm

    5.0

    0.25

    14.002 14.013

    14.043

    13.995 14.000

    13.975

    - - - - - 0.002 0.018

    0.068

    (

    ( ) 0.10 0.25

    0.40

    0.030 0.065

    0.100

    2

    (

    ( ) 0.10 0.25

    0.40

    0.020 0.055

    0.100

    (

    ( ) 0.20 0.70

    0.040 0.160

    Piston ring

    2-6

    ENGINE SPECIFICATIONS

    HD

    TB

    BT

    B

    T

  • 2-7

    ENGINE SPECIFICATIONS

    Connecting rod

    Crankshaft

    Balancer

    Clutch

    Transmission

    Small end inside diameter 14.01514.028 mmConnected Rod Length 99.90100.10 mm

    WidthA 47.9548.00 mmRunout limit C 0.030 mmBig end side clearance D 0.1100.410 mmBig end radial clearance E 0.0040.014 mm

    Balancer drive method Gear

    Clutch type Wet, multiple-discClutch release method Inner push, cam pushClutch lever free play 10.015.0 mmFriction plate thickness 2.903.10 mmWear limit 2.80 mmPlate quantity 1 pcFriction plate 2 thickness 2.903.10 mmWear limit 2.80 mmPlate quantity 4 pcClutch plate thickness 1.451.75 mmPlate quantity 4 pcsWarpage limit 0.20 mmClutch spring free length 39.00 mmMinimum length 36.80 mmSpring quantity 4 pcsPush rod bending limit 0.500 mm

    Transmission type Constant mesh 6-speedPrimary reduction system spur gearPrimary reduction ratio 73/24 (3.042)Secondary reduction system Chain driveSecondary reduction ratio 42/14 (3.000)Operation Left foot operationGear ratio1st 34/12 (2.833)

    2-8

    nd

    rd 2 364

    th

    th

    6th 21/25 (0.840)

    Shift mechanism type Shift drum and guide bar

    Shift fork L thickness mm

    Device type Auto Decompression

    Air filter element Dry element

    Modelquantity H

    Typequantity AC

    Manufacturer MIKUNI

    Throttle valve size

    Crankshaft position sensor resistance at C

    Intake air pressure sensor output voltage V at kPa

    Intake air temperature sensor resistance k

    Coolant temperature sensor resistance at

    Engine idling speed rmin

    Water temperature C (185.00-203.00

    Oil temperature

    Throttle cable free play mm

    2 30/16 (1.875)

    3 30/2 (1. )

    4 24/21 (1.143)

    5 22/23 (0.957)

    - 5.76 5.89

    / 1100 87 10/1

    / 28/1

    #50

    248 372 20

    0.789 4.000 20.00 101.32

    5.7 6.3

    310 326 80

    1300 1500 /

    85.0 95.0

    50.0 70.0 158.00

    3.0 5.0

    Shifting mechanism

    Decompression device

    Air filter

    Fuel injector

    Throttle body

    Fuel injection sensor

    Idling condition

    0

    0

    0

    0

    0 0

    C

    F)

    C (112.00- F

  • 2-7

    Connecting rod

    Crankshaft

    Balancer

    Clutch

    Transmission

    Small end inside diameter 14.01514.028 mmConnected Rod Length 99.90100.10 mm

    WidthA 47.9548.00 mmRunout limit C 0.030 mmBig end side clearance D 0.1100.410 mmBig end radial clearance E 0.0040.014 mm

    Balancer drive method Gear

    Clutch type Wet, multiple-discClutch release method Inner push, cam pushClutch lever free play 10.015.0 mmFriction plate thickness 2.903.10 mmWear limit 2.80 mmPlate quantity 1 pcFriction plate 2 thickness 2.903.10 mmWear limit 2.80 mmPlate quantity 4 pcClutch plate thickness 1.451.75 mmPlate quantity 4 pcsWarpage limit 0.20 mmClutch spring free length 39.00 mmMinimum length 36.80 mmSpring quantity 4 pcsPush rod bending limit 0.500 mm

    Transmission type Constant mesh 6-speedPrimary reduction system spur gearPrimary reduction ratio 73/24 (3.042)Secondary reduction system Chain driveSecondary reduction ratio 42/14 (3.000)Operation Left foot operationGear ratio1st 34/12 (2.833)

    2-8

    ENGINE SPECIFICATIONS

    nd

    rd 2 364

    th

    th

    6th 21/25 (0.840)

    Shift mechanism type Shift drum and guide bar

    Shift fork L thickness mm

    Device type Auto Decompression

    Air filter element Dry element

    Modelquantity H

    Typequantity AC

    Manufacturer MIKUNI

    Throttle valve size

    Crankshaft position sensor resistance at C

    Intake air pressure sensor output voltage V at kPa

    Intake air temperature sensor resistance k

    Coolant temperature sensor resistance at

    Engine idling speed rmin

    Water temperature C (185.00-203.00

    Oil temperature

    Throttle cable free play mm

    2 30/16 (1.875)

    3 30/2 (1. )

    4 24/21 (1.143)

    5 22/23 (0.957)

    - 5.76 5.89

    / 1100 87 10/1

    / 28/1

    #50

    248 372 20

    0.789 4.000 20.00 101.32

    5.7 6.3

    310 326 80

    1300 1500 /

    85.0 95.0

    50.0 70.0 158.00

    3.0 5.0

    Shifting mechanism

    Decompression device

    Air filter

    Fuel injector

    Throttle body

    Fuel injection sensor

    Idling condition

    0

    0

    0

    0

    0 0

    C

    F)

    C (112.00- F

  • 2-9

    CHASSIS SPECIFICATIONS

    CHASSIS SPECIFICATIONS

    Chassis

    Front wheel

    Rear wheel

    Front tyre

    Rear tyre

    Tyre air pressure measured on cold tyres

    Front brake

    Frame type

    Caster angle

    Trail 100.0 mm

    Wheel type Cast wheel

    Rim size x 1.60.

    Rim material Aluminum

    Wheel travel mm

    Radial wheel runout limit mm

    Lateral wheel runout limit mm

    Wheel type Cast wheel

    Rim size M/C x MT 2.15

    Rim material Aluminum

    Wheel travel 05 mm

    Radial wheel runout limit mm

    Lateral wheel runout limit mm

    Type TubelessSize 80/90-17M/C 44P

    Manufacturermodel MRF / ZAPPER

    Type Tubeless

    Size 1008 MC 52P

    Manufacturermodel MRF / ZAPPER

    Front 200

    Rear 25 kPa

    Type Single disc brakeOperation Right hand operation

    26.00

    17

    115.0

    1.0

    0.5

    17

    1 .0

    1.0

    0.5

    /

    / 0 17 /

    /

    ( )

    2

    kPa

    Delta Box

    2-10

    Disc outside diameter & thickness 267.0 x 4.0 mmBrake disc thickness limit 3.5 mmBrake disc deflection limit 0.10 mmBrake pad lining thickness (inner) 5.3 mmLimit 0.8 mmBrake pad lining thickness (outer) 5.3 mmLimit 0.8 mmMaster cylinder inside diameter 11.00 mmCaliper cylinder inside diameter 25.40 mm x 2Recommended fluid DOT 3 or DOT 4

    Type Disk brakeOperation Right foot operationBrake pedal position 44 mm

    Steering bearing type Ball and angular bearingCenter to lock angle (left) 35.0Center to lock angle (right) 35.0

    Type Telescopic forkSpring/shock absorber type Coil spring/oil damperFront fork travel 130.0 mmFork spring free length 384.8 mmLimit 381.8 mmCollar length 88.0 mmInstalled length 381.8 mmSpring rate K1 5 N/mmSpring rate K2 6.75 N/mmSpring stroke K1 075.0 mmSpring stroke K2 75.0130 mmInner tube outer diameter 33.0 mmOptional spring available NoRecommended oil Fork oil 10W or equivalentQuantity 240 cmLevel 126.0 mm

    Type Swingarm (Link suspension)Spring/shock absorber type Coil spring/oil damperRear shock absorber assembly travel 50.0 mm

    Front disc brake

    Rear brake

    Steering

    Front suspension

    Rear suspension

    Rear disc brakeDisc outside diameter & thickness 203.0 x 4.5 mmBrake disc thickness limit 4.0 mmBrake disc deflection limit 0.1 mmBrake pad lining thickness (inner) 7.0 mmLimit 1.5 mmBrake pad lining thickness (outer) 7.0 mmLimit 1.5 mmMaster cylinder inside diameter 12.7 mmCaliper cylinder inside diameter 32.0 mmRecommended fluid DOT 3 or DOT 4

  • 2-9

    CHASSIS SPECIFICATIONS

    Chassis

    Front wheel

    Rear wheel

    Front tyre

    Rear tyre

    Tyre air pressure measured on cold tyres

    Front brake

    Frame type

    Caster angle

    Trail 100.0 mm

    Wheel type Cast wheel

    Rim size x 1.60.

    Rim material Aluminum

    Wheel travel mm

    Radial wheel runout limit mm

    Lateral wheel runout limit mm

    Wheel type Cast wheel

    Rim size M/C x MT 2.15

    Rim material Aluminum

    Wheel travel 05 mm

    Radial wheel runout limit mm

    Lateral wheel runout limit mm

    Type TubelessSize 80/90-17M/C 44P

    Manufacturermodel MRF / ZAPPER

    Type Tubeless

    Size 1008 MC 52P

    Manufacturermodel MRF / ZAPPER

    Front 200

    Rear 25 kPa

    Type Single disc brakeOperation Right hand operation

    26.00

    17

    115.0

    1.0

    0.5

    17

    1 .0

    1.0

    0.5

    /

    / 0 17 /

    /

    ( )

    2

    kPa

    Delta Box

    2-10

    CHASSIS SPECIFICATIONS

    Disc outside diameter & thickness 267.0 x 4.0 mmBrake disc thickness limit 3.5 mmBrake disc deflection limit 0.10 mmBrake pad lining thickness (inner) 5.3 mmLimit 0.8 mmBrake pad lining thickness (outer) 5.3 mmLimit 0.8 mmMaster cylinder inside diameter 11.00 mmCaliper cylinder inside diameter 25.40 mm x 2Recommended fluid DOT 3 or DOT 4

    Type Disk brakeOperation Right foot operationBrake pedal position 44 mm

    Steering bearing type Ball and angular bearingCenter to lock angle (left) 35.0Center to lock angle (right) 35.0

    Type Telescopic forkSpring/shock absorber type Coil spring/oil damperFront fork travel 130.0 mmFork spring free length 384.8 mmLimit 381.8 mmCollar length 88.0 mmInstalled length 381.8 mmSpring rate K1 5 N/mmSpring rate K2 6.75 N/mmSpring stroke K1 075.0 mmSpring stroke K2 75.0130 mmInner tube outer diameter 33.0 mmOptional spring available NoRecommended oil Fork oil 10W or equivalentQuantity 240 cmLevel 126.0 mm

    Type Swingarm (Link suspension)Spring/shock absorber type Coil spring/oil damperRear shock absorber assembly travel 50.0 mm

    Front disc brake

    Rear brake

    Steering

    Front suspension

    Rear suspension

    Rear disc brakeDisc outside diameter & thickness 203.0 x 4.5 mmBrake disc thickness limit 4.0 mmBrake disc deflection limit 0.1 mmBrake pad lining thickness (inner) 7.0 mmLimit 1.5 mmBrake pad lining thickness (outer) 7.0 mmLimit 1.5 mmMaster cylinder inside diameter 12.7 mmCaliper cylinder inside diameter 32.0 mmRecommended fluid DOT 3 or DOT 4

  • 2-11

    CHASSISSPECIFICATIONS

    Spring free length 166.8 mmInstalled length 156.5 mmSpring rate K1 90.00 N/mmSpring stroke K1 0.050.0 mmOptional spring available No

    Swingarm end free play limit (axial) 2.4 mm

    Type/manufacturer 428VI3/DAIDOLink quantity 120Drive chain slack 2040 mm15-link length limit 190.5 mm

    Swingarm

    Drive chain

    ELECTRICAL SPECIFICATIONS

    Voltage

    Ignition system

    Engine control unit

    Ignition coil

    Spark plug cap

    AC magneto

    Rectifierregulator

    Battery

    Headlight

    Bulb voltage wattage & qty.

    System voltage V

    Ignition system Transistorized coil ignition digital

    Advancer type Digital

    Ignition timing BTDC /1400 r/min

    Modelmanufacturer C MORIC

    Primary coil resistance at C

    Secondary coil resistance k at

    Material ResinResistance 5 Kohms

    Modelmanufacturer F C PT MORIC

    Standard output V W @ rpm

    Stator coil resistance at

    Regulator type Semi conductor short circuit

    Regulated voltage DC V

    Rectifier capacity A

    Withstand voltage V

    Model VRLA

    Voltage capacity V Ah

    Ten hour rate amperage 3.50 A

    Bulb type Halogen bulb

    Headlight V x2

    Tailbrake light V W W x 1

    Front turn signal light V W x 2

    Rear turn signal light V W x 2

    Meter lighting L.E.D.Position light 12V, 5.0Wx2

    12

    ( )

    ( . . . .) 5.0

    / 3 100/

    2.16 2.64 20

    8.64 12.96

    / 3 1/

    14.0 160 5000

    0.448 0.672

    /

    -

    ( ) 14.1 14.9

    14.0

    200.0

    , 12 , 3.5

    ,

    12 , 35

    / 12 , 5.0 /21.0

    12 , 10.0

    12 , 10.0

    0

    0

    20

    20

    C

    C

    0

    0

    2-12

    ELECTRICAL SPECIFICATIONS

  • 2-11

    CHASSISSPECIFICATIONS

    Spring free length 166.8 mmInstalled length 156.5 mmSpring rate K1 90.00 N/mmSpring stroke K1 0.050.0 mmOptional spring available No

    Swingarm end free play limit (axial) 2.4 mm

    Type/manufacturer 428VI3/DAIDOLink quantity 120Drive chain slack 2040 mm15-link length limit 190.5 mm

    Swingarm

    Drive chain

    ELECTRICAL SPECIFICATIONS

    Voltage

    Ignition system

    Engine control unit

    Ignition coil

    Spark plug cap

    AC magneto

    Rectifierregulator

    Battery

    Headlight

    Bulb voltage wattage & qty.

    System voltage V

    Ignition system Transistorized coil ignition digital

    Advancer type Digital

    Ignition timing BTDC /1400 r/min

    Modelmanufacturer C MORIC

    Primary coil resistance at C

    Secondary coil resistance k at

    Material ResinResistance 5 Kohms

    Modelmanufacturer F C PT MORIC

    Standard output V W @ rpm

    Stator coil resistance at

    Regulator type Semi conductor short circuit

    Regulated voltage DC V

    Rectifier capacity A

    Withstand voltage V

    Model VRLA

    Voltage capacity V Ah

    Ten hour rate amperage 3.50 A

    Bulb type Halogen bulb

    Headlight V x2

    Tailbrake light V W W x 1

    Front turn signal light V W x 2

    Rear turn signal light V W x 2

    Meter lighting L.E.D.Position light 12V, 5.0Wx2

    12

    ( )

    ( . . . .) 5.0

    / 3 100/

    2.16 2.64 20

    8.64 12.96

    / 3 1/

    14.0 160 5000

    0.448 0.672

    /

    -

    ( ) 14.1 14.9

    14.0

    200.0

    , 12 , 3.5

    ,

    12 , 35

    / 12 , 5.0 /21.0

    12 , 10.0

    12 , 10.0

    0

    0

    20

    20

    C

    C

    0

    0

    2-12

    ELECTRICAL SPECIFICATIONS

  • 2-13

    ELECTRICAL SPECIFICATIONS

    Indicator light

    Electric starting system

    Starter motor

    Starter relay

    Horn

    Turn signal relay

    Fuel sender

    Starting circuit cut-off relay

    Fan motor relay

    Neutral indicator light LEDTurn signal indicator lightHigh beam indicator lightCoolant temperature warning lightEngine trouble warning light

    System type Constant mesh

    Model/manufacturer 3C1/PT. MORICPower output 0.20 kWArmature coil resistance 0.03150.0385Brush overall length 7.0 mmLimit 3.50 mmBrush spring force 3.925.88 NCommutator diameter 17.6 mmLimit 16.6 mmMica undercut (depth) 1.35 mm

    Model/manufacturer 5TP/OMRON-LOCALAmperage 100ACoil resistance 3.424.18

    Horn type PlaneQuantity 1 pcModel/manufacturer Local MadeMaximum amperage 1.5ACoil resistance 4.304.80 at 20 CPerformance 108115 dB/2 m

    Relay type Full TransistorModel/manufacturer Local MadeBuilt-in, self-canceling device NoTurn signal blinking frequency 70-100 cycles/min

    Model/manufacturer Local MadeSender unit resistance (full) 4.010.0 at 20 CSender unit resistance (empty) 90.0100.0 at 20 C

    Model/manufacturer Local MadeCoil resistance 90.0110.0

    Model/manufacturer Local Made

    LEDLEDLEDLED

    2-14

    ELECTRICAL SPECIFICATIONS

    Coil resistance 54.066.0

    Fuse 20.0A

    Fuse

  • 2-13

    ELECTRICAL SPECIFICATIONS

    Indicator light

    Electric starting system

    Starter motor

    Starter relay

    Horn

    Turn signal relay

    Fuel sender

    Starting circuit cut-off relay

    Fan motor relay

    Neutral indicator light LEDTurn signal indicator lightHigh beam indicator lightCoolant temperature warning lightEngine trouble warning light

    System type Constant mesh

    Model/manufacturer 3C1/PT. MORICPower output 0.20 kWArmature coil resistance 0.03150.0385Brush overall length 7.0 mmLimit 3.50 mmBrush spring force 3.925.88 NCommutator diameter 17.6 mmLimit 16.6 mmMica undercut (depth) 1.35 mm

    Model/manufacturer 5TP/OMRON-LOCALAmperage 100ACoil resistance 3.424.18

    Horn type PlaneQuantity 1 pcModel/manufacturer Local MadeMaximum amperage 1.5ACoil resistance 4.304.80 at 20 CPerformance 108115 dB/2 m

    Relay type Full TransistorModel/manufacturer Local MadeBuilt-in, self-canceling device NoTurn signal blinking frequency 70-100 cycles/min

    Model/manufacturer Local MadeSender unit resistance (full) 4.010.0 at 20 CSender unit resistance (empty) 90.0100.0 at 20 C

    Model/manufacturer Local MadeCoil resistance 90.0110.0

    Model/manufacturer Local Made

    LEDLEDLEDLED

    2-14

    ELECTRICAL SPECIFICATIONS

    Coil resistance 54.066.0

    Fuse 20.0A

    Fuse

  • 2-15

    TIGHTENINGTORQUES

    TIGHTENINGTORQUES

    GENERAL TIGHTENINGTORQUESPECIFICATIONSThis chart specifies tightening torques forstandard fasteners with a standard ISO threadpitch. Tightening torque specifications for specialcomponents or assemblies are provided for eachchapter of this manual. To avoid warpage, tightenmulti-fastener assemblies in a crisscross patternand progressive stages until the specifiedtightening torque is reached. Unless otherwisespecified, tightening torque specifications requireclean, dry threads. Components should be atroom temperature.

    2-16

    TIGHTENINGTORQUES

    A. Distance between flats

    B. Outside thread diameter

    A (nut) B (bolt)

    General tighteningtorques

    Nm mkg ftlb

    10 mm 6 mm 6 0.6 4.3

    12 mm 8 mm 15 1.5 11

    14 mm 10 mm 30 3.0 22

    17 mm 12 mm 55 5.5 40

    19 mm 14 mm 85 8.5 61

    22 mm 16 mm 130 13.0 94

    ENGINE TIGHTENING TORQUES

    Itemsize

    ty Tightening torque Remarks

    Cylinderheadbolt M8 4 22Nm(2.2mkg, 16 ftlb)

    Cylinder head bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Spark plug M10 1 13 Nm (1.3 mkg, 9.4 ftlb)

    Cylinder head cover bolt M6 5 10 Nm (1.0 mkg, 7.2 ftlb)

    Air cut-off valve assembly bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Oil check bolt M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Cylinder head stud bolt (exhaustpipe)

    M8 2 15 Nm (1.5 mkg, 11 ftlb)

    Coolant drain bolt M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Balancer driven gear nut M10 1 50 Nm (5.0 mkg, 36 ftlb)

    Valve adjusting screw locknut M5 4 7 Nm (0.7 mkg, 5.1 ftlb)

    Camshaft sprocket bolt M8 1 30 Nm (3.0 mkg, 22 ftlb)

    Camshaft retainer bolt M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Timing chain guide bolt M6 1 10 Nm (1.0 mkg, 7.2 ftlb)

    Timing chain tensioner bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Yamahabond No.

    1215(Threebond

    1215)

    Water pump assembly bolt M6 3 10 Nm (1.0 mkg, 7.2 ftlb)

    Water pump housing cover bolt M6 4 10 Nm (1.0 mkg, 7.2 ftlb)

    Impeller shaft retainer bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Thermostat cover bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Oil pump assembly screw M5 2 4 Nm (0.4 mkg, 2.9 ftlb)

    Engineoildrainplug M35 1 32Nm(3.2mkg, 23 ftlb)

    Oil filter element cover bolt M6 3 10 Nm (1.0 mkg, 7.2 ftlb)

    Oil baffle plate bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Intake manifold bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Injector bolt M6 1 12 Nm (1.2 mkg, 8.7 ftlb)

    Throttle body joint clamp screw M4 2 2 Nm (0.2 mkg, 1.4 ftlb)

    Air filter case joint clamp screw M4 1 2 Nm (0.2 mkg, 1.4 ftlb)

    Air filter case bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Resonator bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Locknut (throttle cable) M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Muffler nut M8 2 15 Nm (1.5 mkg, 11 ftlb)

    Muffler bolt M8 2 20 Nm (2.0 mkg, 14 ftlb)

    Exhaust pipe protector screw M6 2 8 Nm (0.8 mkg, 5.8 ftlb)

  • 2-15

    TIGHTENINGTORQUES

    TIGHTENINGTORQUES

    GENERAL TIGHTENINGTORQUESPECIFICATIONSThis chart specifies tightening torques forstandard fasteners with a standard ISO threadpitch. Tightening torque specifications for specialcomponents or assemblies are provided for eachchapter of this manual. To avoid warpage, tightenmulti-fastener assemblies in a crisscross patternand progressive stages until the specifiedtightening torque is reached. Unless otherwisespecified, tightening torque specifications requireclean, dry threads. Components should be atroom temperature.

    2-16

    TIGHTENINGTORQUES

    A. Distance between flats

    B. Outside thread diameter

    A (nut) B (bolt)

    General tighteningtorques

    Nm mkg ftlb

    10 mm 6 mm 6 0.6 4.3

    12 mm 8 mm 15 1.5 11

    14 mm 10 mm 30 3.0 22

    17 mm 12 mm 55 5.5 40

    19 mm 14 mm 85 8.5 61

    22 mm 16 mm 130 13.0 94

    ENGINE TIGHTENING TORQUES

    ItemThread

    sizeQty Tightening torque Remarks

    Cylinderheadbolt M8 4 22Nm(2.2mkg, 16 ftlb)

    Cylinder head bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Spark plug M10 1 13 Nm (1.3 mkg, 9.4 ftlb)

    Cylinder head cover bolt M6 5 10 Nm (1.0 mkg, 7.2 ftlb)

    Air cut-off valve assembly bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Oil check bolt M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Cylinder head stud bolt (exhaustpipe)

    M8 2 15 Nm (1.5 mkg, 11 ftlb)

    Coolant drain bolt M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Balancer driven gear nut M10 1 50 Nm (5.0 mkg, 36 ftlb)

    Valve adjusting screw locknut M5 4 7 Nm (0.7 mkg, 5.1 ftlb)

    Camshaft sprocket bolt M8 1 30 Nm (3.0 mkg, 22 ftlb)

    Camshaft retainer bolt M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Timing chain guide bolt M6 1 10 Nm (1.0 mkg, 7.2 ftlb)

    Timing chain tensioner bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Yamahabond No.

    1215(Threebond

    1215)

    Water pump assembly bolt M6 3 10 Nm (1.0 mkg, 7.2 ftlb)

    Water pump housing cover bolt M6 4 10 Nm (1.0 mkg, 7.2 ftlb)

    Impeller shaft retainer bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Thermostat cover bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Oil pump assembly screw M5 2 4 Nm (0.4 mkg, 2.9 ftlb)

    Engineoildrainplug M35 1 32Nm(3.2mkg, 23 ftlb)

    Oil filter element cover bolt M6 3 10 Nm (1.0 mkg, 7.2 ftlb)

    Oil baffle plate bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Intake manifold bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Injector bolt M6 1 12 Nm (1.2 mkg, 8.7 ftlb)

    Throttle body joint clamp screw M4 2 2 Nm (0.2 mkg, 1.4 ftlb)

    Air filter case joint clamp screw M4 1 2 Nm (0.2 mkg, 1.4 ftlb)

    Air filter case bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Resonator bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Locknut (throttle cable) M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Muffler nut M8 2 15 Nm (1.5 mkg, 11 ftlb)

    Muffler bolt M8 2 20 Nm (2.0 mkg, 14 ftlb)

    Exhaust pipe protector screw M6 2 8 Nm (0.8 mkg, 5.8 ftlb)

    E

    E

    LT

    LT

    LT

    LT

    LT

    LT

  • 2-17

    TIGHTENINGTORQUES

    2-18

    TIGHTENINGTORQUES

    Muffler protector screw M6 2 8 Nm (0.8 mkg, 5.8 ftlb)

    Crankcase bolt M6 12 10 Nm (1.0 mkg, 7.2 ftlb)

    Magneto cover bolt M6 8 10 Nm (1.0 m kg, 7.2 ftlb)

    Clutch cover bolt M6 10 10 Nm (1.0 mkg, 7.2 ftlb)

    Drive sprocket cover bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Starter clutch bolt M6 3 14 Nm (1.4 mkg, 10 ftlb) Stake

    Primary drive gear nut M12 1 60 Nm (6.0 mkg, 43 ftlb)

    Clutch spring bolt M6 4 12 Nm (1.2 mkg, 8.7 ftlb)

    Locknut short clutch push rod M6 1 8 Nm (0.8 mkg, 5.8 ftlb)

    Clutchbossnut M14 1 70Nm(7.0mkg, 50 ftlb)

    Clutch cable locknut M8 1 9 Nm (0.9 mkg, 6.5 ftlb)

    Clutch lever nut M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Clutchleverholderbolt M6 1 7 Nm(0.7mkg, 5.1 ftlb)

    Drive sprocket retainer bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Bearingretainerscrew M6 2 7Nm(0.7 mkg, 5.1 ftlb)

    Shiftdrumsegmentbolt M6 1 12Nm(1.2 mkg, 8.7 ftlb)

    Stopper lever bolt M6 1 10 Nm (1.0 mkg, 7.2 ftlb)

    Stator coil bolt M6 3 10 Nm (1.0 mkg, 7.2 ftlb)

    Crankshaft position sensor bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Magneto rotor nut M12 1 70 Nm (7.0 mkg, 50 ftlb)

    Neutral switch M10 1 20 Nm (2.0 mkg, 14 ftlb)

    Starter motor bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Coolant temperature sensor M12 1 18 Nm (1.8 mkg, 13 ftlb)

    ItemThread

    sizeQty Tightening torque Remarks

    LT

    LT

    LT

    LT

    LT

    LT

    Cylinder head tightening sequence:

    Magneto cover tightening sequence:

    Clutch cover tightening sequence:

  • 2-17

    TIGHTENINGTORQUES

    2-18

    TIGHTENINGTORQUES

    Muffler protector screw M6 2 8 Nm (0.8 mkg, 5.8 ftlb)

    Crankcase bolt M6 12 10 Nm (1.0 mkg, 7.2 ftlb)

    Magneto cover bolt M6 8 10 Nm (1.0 m kg, 7.2 ftlb)

    Clutch cover bolt M6 10 10 Nm (1.0 mkg, 7.2 ftlb)

    Drive sprocket cover bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Starter clutch bolt M6 3 14 Nm (1.4 mkg, 10 ftlb) Stake

    Primary drive gear nut M12 1 60 Nm (6.0 mkg, 43 ftlb)

    Clutch spring bolt M6 4 12 Nm (1.2 mkg, 8.7 ftlb)

    Locknut short clutch push rod M6 1 8 Nm (0.8 mkg, 5.8 ftlb)

    Clutchbossnut M14 1 70Nm(7.0mkg, 50 ftlb)

    Clutch cable locknut M8 1 9 Nm (0.9 mkg, 6.5 ftlb)

    Clutch lever nut M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Clutchleverholderbolt M6 1 7 Nm(0.7mkg, 5.1 ftlb)

    Drive sprocket retainer bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Bearingretainerscrew M6 2 7Nm(0.7 mkg, 5.1 ftlb)

    Shiftdrumsegmentbolt M6 1 12Nm(1.2 mkg, 8.7 ftlb)

    Stopper lever bolt M6 1 10 Nm (1.0 mkg, 7.2 ftlb)

    Stator coil bolt M6 3 10 Nm (1.0 mkg, 7.2 ftlb)

    Crankshaft position sensor bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Magneto rotor nut M12 1 70 Nm (7.0 mkg, 50 ftlb)

    Neutral switch M10 1 20 Nm (2.0 mkg, 14 ftlb)

    Starter motor bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Coolant temperature sensor M12 1 18 Nm (1.8 mkg, 13 ftlb)

    ItemThread

    sizeQty Tightening torque Remarks

    Cylinder head tightening sequence:

    Magneto cover tightening sequence:

    Clutch cover tightening sequence:

    4 2

    6

    531

    2,103,11

    4

    5

    1,67

    8

    9

    112,12

    10

    9

    96

    81,7

    3,13

    6

    5

    4

  • 2-19

    TIGHTENINGTORQUES

    2-20

    TIGHTENINGTORQUES

    Crankcase tightening sequence:

    A

    1,61,6

    2,122,125

    4

    3,13 1110

    9

    87

    A. Left crankcase

    B. Right crankcase

    14

    15

    B

    CHASSIS TIGHTENING TORQUES

    Itemsize

    Qty Tightening torque Remarks

    Ignition coil bolt M6 2 9 Nm (0.9 mkg, 6.5 ftlb)

    Engine mounting nut (front side) M10 1 49 Nm (4.9 mkg, 35 ftlb)

    Engine mounting nut (rear lowerside)

    M10 1 49 Nm (4.9 mkg, 35 ftlb)

    Engine mounting nut (rear upperside)

    M10 1 49 Nm (4.9 mkg, 35 ftlb)

    Rear fender bolt M6 6 9 Nm (0.9 mkg, 6.5 ftlb)

    Seat lock bracket M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Rectifier/regulator bolt M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Rear shock absorber assemblyupper nut

    M10 1 44 Nm (4.4 mkg, 32 ftlb)

    Rear wheel axle nut M14 1 110 Nm (11.0 mkg, 80 ft lb)

    Relay arm nut M10 2 44 Nm (4.4 mkg, 32 ftlb)

    Rear shock absorber assemblylower connecting arm nut

    M10 1 44 Nm (4.4 mkg, 32 ftlb)

    Rear shock absorber assemblylower nut

    M10 1 44 Nm (4.4 mkg, 32 ftlb)

    Swingarmpivotshaftnut M12 1 70Nm(7.0mkg, 50 ftlb)

    Drive chain cover bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Brakehoseunionbolt M10 2 26Nm(2.6mkg, 19 ftlb)

    Front brakecaliperbolt M10 2 35Nm(3.5mkg, 25 ftlb)

    Front wheel axle nut M12 1 60 Nm (6.0 mkg, 43 ftlb)

    Front brake disc bolt M8 5 23 Nm (2.3 mkg, 17 ftlb)

    Bleed screw (front brake caliper) M7 1 6 Nm (0.6 mkg, 4.3 ftlb)

    Brake hose holder bolt M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Front fender bolt M6 4 9 Nm (0.9 mkg, 6.5 ftlb)

    Lower ring nut (initial tighteningtorque)

    M25 1 48 Nm (4.8 mkg, 35 ftlb)See

    NOTE.

    Lower ring nut (final tighteningtorque)

    M25 1 13 Nm (1.3 mkg, 9.4 ftlb)See

    NOTE.

    Steering stem bolt M10 1 35 Nm (3.5 mkg, 25 ftlb)

    Meter assembly nut M6 3 7 Nm (0.7 mkg, 5.1 ftlb)

    Headlight housing and front turnsignal light assembly nut

    M8 2 17 Nm (1.7 mkg, 12 ftlb)

    Main switch bolt M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Upper bracket pinch bolt M8 2 23 Nm (2.3 mkg, 17 ftlb)

    Lowerbracketpinchbolt M10 2 28Nm(2.8mkg, 20 ftlb)

    Front fork capbolt M30 2 23Nm(2.3m

    Headlightmountingbolt M12

    kg, 17 ftlb)

    2 33Nm(3.3m.kg,22ft.lb)

  • 2-19

    TIGHTENINGTORQUES

    2-20

    TIGHTENINGTORQUES

    Crankcase tightening sequence:

    A

    A. Left crankcase

    B. Right crankcase

    15

    B

    CHASSIS TIGHTENING TORQUES

    ItemThread

    sizeQty Tightening torque Remarks

    Ignition coil bolt M6 2 9 Nm (0.9 mkg, 6.5 ftlb)

    Engine mounting nut (front side) M10 1 49 Nm (4.9 mkg, 35 ftlb)

    Engine mounting nut (rear lowerside)

    M10 1 49 Nm (4.9 mkg, 35 ftlb)

    Engine mounting nut (rear upperside)

    M10 1 49 Nm (4.9 mkg, 35 ftlb)

    Rear fender bolt M6 6 9 Nm (0.9 mkg, 6.5 ftlb)

    Seat lock bracket M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Rectifier/regulator bolt M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Rear shock absorber assemblyupper nut

    M10 1 44 Nm (4.4 mkg, 32 ftlb)

    Rear wheel axle nut M14 1 110 Nm (11.0 mkg, 80 ft lb)

    Relay arm nut M10 2 44 Nm (4.4 mkg, 32 ftlb)

    Rear shock absorber assemblylower connecting arm nut

    M10 1 44 Nm (4.4 mkg, 32 ftlb)

    Rear shock absorber assemblylower nut

    M10 1 44 Nm (4.4 mkg, 32 ftlb)

    Swingarmpivotshaftnut M12 1 70Nm(7.0mkg, 50 ftlb)

    Drive chain cover bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Brakehoseunionbolt M10 2 26Nm(2.6mkg, 19 ftlb)

    Front brakecaliperbolt M10 2 35Nm(3.5mkg, 25 ftlb)

    Front wheel axle nut M12 1 60 Nm (6.0 mkg, 43 ftlb)

    Front brake disc bolt M8 5 23 Nm (2.3 mkg, 17 ftlb)

    Bleed screw (front brake caliper) M7 1 6 Nm (0.6 mkg, 4.3 ftlb)

    Brake hose holder bolt M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Front fender bolt M6 4 9 Nm (0.9 mkg, 6.5 ftlb)

    Lower ring nut (initial tighteningtorque)

    M25 1 48 Nm (4.8 mkg, 35 ftlb)See

    NOTE.

    Lower ring nut (final tighteningtorque)

    M25 1 13 Nm (1.3 mkg, 9.4 ftlb)See

    NOTE.

    Steering stem bolt M10 1 35 Nm (3.5 mkg, 25 ftlb)

    Meter assembly nut M6 3 7 Nm (0.7 mkg, 5.1 ftlb)

    Headlight housing and front turnsignal light assembly nut

    M8 2 17 Nm (1.7 mkg, 12 ftlb)

    Main switch bolt M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Upper bracket pinch bolt M8 2 23 Nm (2.3 mkg, 17 ftlb)

    Lowerbracketpinchbolt M10 2 28Nm(2.8mkg, 20 ftlb)

    Front fork capbolt M30 2 23Nm(2.3m

    Headlightmountingbolt M12

    kg, 17 ftlb)

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LT

    2 33Nm(3.3m.kg,22ft.lb)

  • 2-21

    TIGHTENINGTORQUES

    2-22

    LUBRICATIONPOINTS ANDLUBRICANTTYPES

    NOTE:

    1. First, tighten the lower ring nut to approximately 48 Nm (4.8 mkg, 35 ftlb) with a torque wrench, then

    loosen the lower ring nut completely.

    2. Retightenthelowerringnutto13Nm(1.3mkg, 9.4 ftlb) with a torque wrench.

    Damper rod bolt M10 2 28 Nm (2.8 mkg, 20 ftlb)

    Front turn signal light assemblyand meter assembly bracket bolt

    M6 4 7 Nm (0.7 mkg, 5.1 ftlb)

    Horn bolt M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Fuel tank and frame bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Fuel tank bracket and frame bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Fuel tank and fuel tank bracketbolt

    M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Fuel pump retainer bolt M5 6 4 Nm (0.4 mkg, 2.9 ftlb)

    Rearsidecoverbolt M6 2 7 Nm(0.7mkg, 5.1 ftlb)

    Rear side cover and rear panelbolt

    M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Seat Handle M8 4 26 Nm (2.6 mkg, 19 ftlb)

    Coolant reservoir bolt M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Radiator bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Radiator fan bolt M6 2 8 Nm (0.8 mkg, 5.8 ftlb)

    Grip end screw M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Front brake master cylinder hold-er bolt

    M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Front brake lever bolt M6 1 6 Nm (0.6 mkg, 4.3 ftlb)

    Front brake lever nut M6 1 6 Nm (0.6 mkg, 4.3 ftlb)

    Front panelbolt M6 4 7Nm(0.7 mkg, 5.1 ftlb)

    Side cover bolt M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Rear wheel sprocket nut M8 6 43 Nm (4.3 mkg, 31 ftlb)

    Brake pedal bolt M6 2 22 Nm (1.0 mkg, 7.2 ftlb)

    Right footrest and right heel platebolt

    M10 2 30 Nm (4.5 mkg, 32 ftlb)

    Shift arm bolt M6 2 10 Nm (1.0 m

    kg, 22 ft

    lb)

    Heel plate bolt M8 30 Nm (3.0 m lb)

    Side stand bolt M10 1 44 Nm (4.4 mkg, 32 ftlb)

    ItemThread

    sizeQty Tightening torque Remarks

    LT

    kg, 7.2 ft

    LUBRICATION POINTS AND LUBRICANT TYPES

    ENGINE

    Lubrication point Lubricant

    Oil seal lips

    Bearings

    O-rings

    Cylinder head bolts and washers

    Connectingrodbigend thrustsurface

    Piston, Piston rings, and cylinder inner surface

    Balancer driven gear inner surface

    Camshaft lobes

    Decompression cam

    Valve stem seal

    Valve stem (intake and exhaust)

    Valve stem ends (intake and exhaust)

    Rocker arm shaft

    Rocker arm inner surfaces

    Decompression lever pin

    Oil seal (clutch cover)

    Oil pump driven gear

    Oil pump rotors (inner and outer)

    Starterclutch idlegearthrustsurface

    Starter clutch idle gear shaft

    Starterclutch gearinnersurfaceandthrustsurface

    Starterclutch rollers

    Clutchpushlever

    Primary driven gear inner surface

    Clutch push rod (short and long) and ball

    Clutch boss nut and lock washer contact surface

    Transmission gears (wheel and pinion) and collar

    Shift forks and shift fork guide bar

    Shift drum

    Shift shaft

  • 2-21

    TIGHTENINGTORQUES

    2-22

    LUBRICATIONPOINTS ANDLUBRICANTTYPES

    NOTE:

    1. First, tighten the lower ring nut to approximately 48 Nm (4.8 mkg, 35 ftlb) with a torque wrench, then

    loosen the lower ring nut completely.

    2. Retightenthelowerringnutto13Nm(1.3mkg, 9.4 ftlb) with a torque wrench.

    Damper rod bolt M10 2 28 Nm (2.8 mkg, 20 ftlb)

    Front turn signal light assemblyand meter assembly bracket bolt

    M6 4 7 Nm (0.7 mkg, 5.1 ftlb)

    Horn bolt M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

    Fuel tank and frame bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Fuel tank bracket and frame bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Fuel tank and fuel tank bracketbolt

    M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Fuel pump retainer bolt M5 6 4 Nm (0.4 mkg, 2.9 ftlb)

    Rearsidecoverbolt M6 2 7 Nm(0.7mkg, 5.1 ftlb)

    Rear side cover and rear panelbolt

    M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Seat Handle M8 4 26 Nm (2.6 mkg, 19 ftlb)

    Coolant reservoir bolt M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Radiator bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

    Radiator fan bolt M6 2 8 Nm (0.8 mkg, 5.8 ftlb)

    Grip end screw M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Front brake master cylinder hold-er bolt

    M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Front brake lever bolt M6 1 6 Nm (0.6 mkg, 4.3 ftlb)

    Front brake lever nut M6 1 6 Nm (0.6 mkg, 4.3 ftlb)

    Front panelbolt M6 4 7Nm(0.7 mkg, 5.1 ftlb)

    Side cover bolt M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

    Rear wheel sprocket nut M8 6 43 Nm (4.3 mkg, 31 ftlb)

    Brake pedal bolt M6 2 22 Nm (1.0 mkg, 7.2 ftlb)

    Right footrest and right heel platebolt

    M10 2 30 Nm (4.5 mkg, 32 ftlb)

    Shift arm bolt M6 2 10 Nm (1.0 m

    kg, 22 ft

    lb)

    Heel plate bolt M8 30 Nm (3.0 m lb)

    Side stand bolt M10 1 44 Nm (4.4 mkg, 32 ftlb)

    ItemThread

    sizeQty Tightening torque Remarks

    kg, 7.2 ft

    LUBRICATION POINTS AND LUBRICANT TYPES

    ENGINE

    Lubrication point Lubricant

    Oil seal lips

    Bearings

    O-rings

    Cylinder head bolts and washers

    Connectingrodbigend thrustsurface

    Piston, Piston rings, and cylinder inner surface

    Balancer driven gear inner surface

    Camshaft lobes

    Decompression cam

    Valve stem seal

    Valve stem (intake and exhaust)

    Valve stem ends (intake and exhaust)

    Rocker arm shaft

    Rocker arm inner surfaces

    Decompression lever pin

    Oil seal (clutch cover)

    Oil pump driven gear

    Oil pump rotors (inner and outer)

    Starterclutch idlegearthrustsurface

    Starter clutch idle gear shaft

    Starterclutch gearinnersurfaceandthrustsurface

    Starterclutch rollers

    Clutchpushlever

    Primary driven gear inner surface

    Clutch push rod (short and long) and ball

    Clutch boss nut and lock washer contact surface

    Transmission gears (wheel and pinion) and collar

    Shift forks and shift fork guide bar

    Shift drum

    Shift shaft

    LS

    E

    LS

    E

    E

    E

    E

    M

    E

    M

    M

    M

    E

    M

    M

    E

    E

    E

    E

    E

    E

    E

    E

    E

    E

    E

    M

    E

    E

    E

  • 2-23 2-24

    LUBRICATIONPOINTS ANDLUBRICANTTYPESLUBRICATIONPOINTS ANDLUBRICANTTYPES

    Crankshaft position sensor/stator assembly lead grommetYamaha bond No.1215 (Three Bond

    No.1215)

    Crankcase mating surfaceYamaha bond No.1215 (Three Bond

    No.1215)

    Timing chain tensioner boltsYamaha bond No.1215 (Three Bond

    No.1215)

    Lubrication point Lubricant

    CHASSIS

    Lubrication point Lubricant

    Front wheel oil seal lip

    Front wheel axle outer surface

    Speed sensor unit

    Rear wheel drive hub oil seal lip

    Rear wheel drive hub mating surface

    Rear wheel axle outer surface

    Rearwheelaxleandnutthreads

    Brakepedalpivotingpoint

    Brake caliper bracket boots inner surface

    Throttle grip tube guide inner surface and throttle cable end

    Clutch cable end at the clutch lever

    Brake lever pivot bolt outer surface

    Steering head bearings and upper bearing cover lip

    Steering head dust seal

    Bolt and nut threads (relay arm and flame)

    Bolt and nut threads (connecting rod and relay arm)

    Bolt and nut threads (rear shock absorber and relay arm)

    Bolt and nut threads (connecting rod and swingarm)

    Bearing inner surface (relay arm and swingarm)

    Oil seal lips (relay arm and swingarm)

    Collars (relay arm and swingarm)

    Pivot shaft and nut threads

    Pivot shaft outer surface

    Swingarm bushing outer surface

    Swingarmdustcoverlips

    Sidestand pivoting point and metal-to-metal moving point

    Footrest pivoting point

    Passenger footrest pivoting point

    Shift pedal pivoting point

    Engine mounting bolts and nuts

  • 2-23 2-24

    LUBRICATIONPOINTS ANDLUBRICANTTYPESLUBRICATIONPOINTS ANDLUBRICANTTYPES

    Crankshaft position sensor/stator assembly lead grommetYamaha bond No.1215 (Three Bond

    No.1215)

    Crankcase mating surfaceYamaha bond No.1215 (Three Bond

    No.1215)

    Timing chain tensioner boltsYamaha bond No.1215 (Three Bond

    No.1215)

    Lubrication point Lubricant

    CHASSIS

    Lubrication point Lubricant

    Front wheel oil seal lip

    Front wheel axle outer surface

    Speed sensor unit

    Rear wheel drive hub oil seal lip

    Rear wheel drive hub mating surface

    Rear wheel axle outer surface

    Rearwheelaxleandnutthreads

    Brakepedalpivotingpoint

    Brake caliper bracket boots inner surface

    Throttle grip tube guide inner surface and throttle cable end

    Clutch cable end at the clutch lever

    Brake lever pivot bolt outer surface

    Steering head bearings and upper bearing cover lip

    Steering head dust seal

    Bolt and nut threads (relay arm and flame)

    Bolt and nut threads (connecting rod and relay arm)

    Bolt and nut threads (rear shock absorber and relay arm)

    Bolt and nut threads (connecting rod and swingarm)

    Bearing inner surface (relay arm and swingarm)

    Oil seal lips (relay arm and swingarm)

    Collars (relay arm and swingarm)

    Pivot shaft and nut threads

    Pivot shaft outer surface

    Swingarm bushing outer surface

    Swingarmdustcoverlips

    Sidestand pivoting point and metal-to-metal moving point

    Footrest pivoting point

    Passenger footrest pivoting point

    Shift pedal pivoting point

    Engine mounting bolts and nuts

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    S

    S

    LS

    LS

    S

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    LS

    E

  • 2-25 2-26

    LUBRICATIONPOINTS ANDLUBRICANTTYPESLUBRICATIONPOINTS ANDLUBRICANTTYPES

    LUBRICATION SYSTEM CHART AND DIAGRAMS

    ENGINE OIL LUBRICATION CHART

    1

    6

    5

    2

    4

    3

    2. Oil filter element

    3. Crankshaft

    4. Camshaft

    5. Main axle

    6. Drive axle

    1. Oil pump

  • 2-25 2-26

    LUBRICATIONPOINTS ANDLUBRICANTTYPESLUBRICATIONPOINTS ANDLUBRICANTTYPES

    LUBRICATION SYSTEM CHART AND DIAGRAMS

    ENGINE OIL LUBRICATION CHART

    2. Oil filter element

    3. Crankshaft

    4. Camshaft

    5. Main axle

    6. Drive axle

    1. Oil pump

  • 2-27 2-28

    LUBRICATIONPOINTS ANDLUBRICANTTYPESLUBRICATIONPOINTS ANDLUBRICANTTYPES

    LUBRICATION DIAGRAMS

    A

    1

    2

    3

    4

    5

    6

    7

    1. Clutch push lever

    2. Main axle

    3. Drive axle

    4. Crankshaft

    5. Oil filter

    6. Oil pump assembly

    7. Oil strainer

    A. To cylinder head

  • 2-27 2-28

    LUBRICATIONPOINTS ANDLUBRICANTTYPESLUBRICATIONPOINTS ANDLUBRICANTTYPES

    LUBRICATION DIAGRAMS

    A

    1. Clutch push lever

    2. Main axle

    3. Drive axle

    4. Crankshaft

    5. Oil filter

    6. Oil pump assembly

    7. Oil strainer

    A. To cylinder head

  • 2-29 2-30

    LUBRICATIONPOINTS ANDLUBRICANTTYPESLUBRICATIONPOINTS ANDLUBRICANTTYPES

    1

    2

    3

    4

    1. Camshaft

    2. Crankshaft

    3. Main axle

    4. Drive axle

  • 2-29 2-30

    LUBRICATIONPOINTS ANDLUBRICANTTYPESLUBRICATIONPOINTS ANDLUBRICANTTYPES

    1. Camshaft

    2. Crankshaft

    3. Main axle

    4. Drive axle

  • 2-31 2-32

    COOLINGSYSTEMDIAGRAMS COOLINGSYSTEMDIAGRAMS

    COOLINGSYSTEMDIAGRAMS

    1 2 3

    4

    157

    6

    4

    1. Coolant reservoir

    2. Radiator inlet hose

    3. Coolant reservoir hose

    4. Radiator

    5. Water pump

    6. Radiator outlet hose

    7. Water pump breather hose