yamaha yzf-r15 service manual (english)
DESCRIPTION
service manual for Yamaha R15 V1TRANSCRIPT
-
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