Page 82 of 608

SPEC
2 - 13
MAINTENANCE SPECIFICATIONS
EC212201
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN AUS,
NZ, ZAEUROPE
Front fork travel 300 mm
(11.8 in)¬----
Fork spring free length 460 mm
(18.1 in)¬455 mm (17.9 in)
Spring rate, STD K = 4.6 N/mm
(0.46 kg/mm,
25.8 lb/in)K = 4.5 N/mm
(0.45 kg/mm,
25.2 lb/in)----
Optional spring/spacer Yes¬----
Oil capacity 578 cm
3
(20.3 lmp oz,
19.5 US oz) ¬----
Oil level 130 mm
(5.12 in)¬----
(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)80 ~ 150 mm
(3.15 ~ 5.91 in)¬----
Oil grade Suspension oil
“01”¬----
Inner tube outer diameter 46 mm (1.81 in)¬----
Front fork top end 0 mm (0 in)¬----
Rear suspension: USA, CDN,
AUS, NZ, ZAEUROPE
Shock absorber travel 132 mm
(5.20 in)¬----
Spring free length 265 mm
(10.43 in)275 mm
(10.83 in)----
Fitting length 253 mm
(9.96 in)260 mm
(10.24 in)----
247 ~ 265 mm
(9.72 ~ 10.43 in)257 ~ 275 mm
(10.12 ~ 10.83 in)----
Spring rate, STD K = 54.0 N/mm
(5.40 kg/mm,
302.4 lb/in)K = Approx.
54.0 N/mm
(5.40 kg/mm,
302.4 lb/in)----
Optional spring Yes¬----
Enclosed gas pressure 1,000 kPa
(10 kg/cm
2,
142 psi)¬----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)
Page 86 of 608
SPEC
2 - 17
MAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
C.D.I.:
Magneto-model/manufacturer F5JG/YAMAHA ----
Source coil 1 resistance (color) 720 ~ 1,080 W at 20 ˚C (68 ˚F)
(Green – Brown)----
Source coil 2 resistance (color) 44 ~ 66 W at 20 ˚C (68 ˚F)
(Black – Pink)----
Pickup coil resistance (color) 248 ~ 372 W at 20 ˚C (68 ˚F)
(White – Red)----
CDI unit-model/manufacturer 5JG/YAMAHA ----
Ignition coil:
Model/manufacturer JF2/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.20 ~ 0.30 W at 20 ˚C (68 ˚F) ----
Secondary winding resistance 9.5 ~ 14.3 kW at 20 ˚C (68 ˚F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M6 ´ 1.0 3 10 1.0 7.2
Rotor M10 ´ 1.25 1 48 4.8 35
Ignition coil M6 ´ 1.0 2 7 0.7 5.1
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2 - 5
CARACTERISTIQUES D’ENTRETIEN
SPEC
Limite de voile d’arbre à cames ---- 0,03 mm
(0,0012 in)
Chaîne de distribution:
Type de chaîne de distribution/nbre de maillons 92RH2010-120MPX/120 ----
Méthode de réglage de la chaîne de distribution Automatique ----
Soupape, siège de soupape, guide de soupape:
Jeu de soupape (à froid) AD 0,15 à 0,20 mm
(0,0059 à 0,0079 in)----
ECH 0,25 à 0,30 mm
(0,0098 à 0,0118 in)----
Dimensions des soupapes:
“A” diamètre de tête AD 26,9 à 27,1 mm
(1,0591 à 1,0669 in)----
ECH 27,9 à 28,1 mm
(1,0984 à 1,1063 in)----
“B” largeur de face AD 2,26 mm (0,089 in) ----
ECH 2,26 mm (0,089 in) ----
“C” largeur de siège AD0,9 à 1,1 mm (0,0354 à 0,0433 in)1,5 mm
(0,0591 in)
ECH 0,9 à 1,1 mm (0,0354 à 0,0433 in)1,5 mm
(0,0591 in)
“D” épaisseur de rebord AD 1 mm (0,0394 in) 0,85 mm
(0,033 in)
ECH 1 mm (0,0394 in) 0,85 mm
(0,033 in)
Diamètre extérieur de queue AD4,475 à 4,490 mm
(0,1762 à 0,1768 in)----
ECH 4,960 à 4,975 mm
(0,1953 à 0,1959 in)----
Diamètre intérieur du guide AD 4,500 à 4,512 mm
(0,1772 à 0,1776 in)----
ECH 5,000 à 5,012 mm
(0,1969 à 0,1973 in)----
Jeu entre queue et guide AD0,010 à 0,037 mm
(0,0004 à 0,0015 in)0,08 mm
(0,003 in)
ECH 0,025 à 0,052 mm
(0,0010 à 0,0020 in)0,10 mm
(0,004 in) Article Standard Limite
A
Diamètre de tête
B
Largeur de faceC
Largeur de siège
D
Épaisseur de marge
Epaisseur de rebord
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2 - 14
CARACTERISTIQUES D’ENTRETIENSPEC
Roue:
Type de roue avant Roue à rayons ----
Type de roue arrière Roue à rayons ----
Taille/matériau de jante avant 21 ´ 1,60/aluminum ----
Taille/matériau de jante arrière 19 ´ 2,15/aluminum ----
Limite de voile de jante:
Radial ---- 2,0 mm (0,08 in)
Latéral ---- 2,0 mm (0,08 in)
Chaîne de transmission:
Type/fabricant 520DM-DHA/DAIDO ----
Nombre de maillons 113 maillons + attache ----
Flèche de la chaîne 40 à 50 mm (1,6 à 2,0 in) ----
Longueur de chaîne (10 maillons) ----152,5 mm (6,00 in)
Frein à disque avant:
Diamètre extérieur ´ épaisseur 245 ´ 3,0 mm (9,65 ´ 0,12 in) 245 ´ 2,5 mm
(9,65 ´ 0,08 in)
Limite de flèche ----0,15 mm (0,006 in)
Epaisseur de plaquette 4,4 mm (0,17 in) 1 mm (0,04 in)
Diamètre intérieur de maître-cylindre 11,0 mm (0,433 in) ----
Diamètre intérieur de cylindre d’étrier 27,0 mm (1,063 in) ´ 2 ----
Type de liquide de frein DOT n˚4 ----
Frein à disque arrière:
Diamètre extérieur ´ épaisseur 240 ´ 4,0 mm (9,45 ´ 0,16 in) 240 ´ 3,5 mm
(9,45 ´ 0,14 in)
Limite de flèche ----0,15 mm (0,006 in)
Epaisseur de plaquette 6,4 mm (0,25 in) 1,0 mm (0,04 in)
Diamètre intérieur de maître-cylindre 12,7 mm (0,500 in) ----
Diamètre intérieur de cylindre d’étrier 27,0 mm (1,063 in) ´ 1 ----
Type de liquide de frein DOT n˚4 ----
Levier de frein et pédale de frein:
Position du levier de frein 82,5 mm (3,25 in) ----
Hauteur de la pédale de frein
(hauteur en dessous le haut du repose-pied)5 mm (0,20 in) ----
Jeu de levier d’embrayage (au pivot du levier) 2 à 4 mm (0,08 à 0,16 in) ----
Jeu à la poignée d’accélération 3 à 5 mm (0,12 à 0,20 in) ----Article Standard Limite
Page 124 of 608
2 - 19
SPEC
LUBRICATION DIAGRAMS
LUBRICATION DIAGRAMS
1
Oil delivery pipe
2
Intake camshaft
3
Exhaust camshaft
4
Oil filter
5
Oil pump
6
Main axle
7
Drive axle
Page 126 of 608
2 - 20
SPEC
LUBRICATION DIAGRAMS
1
Camshaft
2
Connecting rod
3
Oil filter
4
Crankshaft
5
Main axle
6
Drive axle
7
Oil delivery pipe
Page 128 of 608

2 - 21
SPEC
CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1
Hose guide
2
Brake hose
3
Fuel tank breather hose
4
Oil tank breather hose
5
Clamp
6
“ENGINE STOP” button lead
7
Sub wire harness
8
TPS (throttle position sensor)
lead
9
Neutral switch lead
0
Oil hose
A
Hose holder
B
CDI magneto lead
C
Clutch cable
D
Cylinder head breather hose
E
Carburetor breather hose
F
Overflow hose
Pass the clutch cable through
the cable guide.
õ
Pass the fuel tank breather
hose between the handlebar
and tension bar, then insert its
end into the hole of the num-
ber plate.
‚
Pass the decompression cable
and “ENGINE STOP” button
lead under the frame.
ë
Pass the “ENGINE STOP” but-
ton lead along the inner side of
the decompression cable.
ä
Fasten the CDI magneto lead,
neutral switch lead and
“ENGINE STOP” button lead
to the frame with a plastic lock-
ing tie and cut off the tie end.
ì
Pass the “ENGINE STOP”
button lead along the inner
side of the oil tank breather
hose.
í
Fasten the sub wire harness
and “ENGINE STOP” button
lead to the frame with a plas-
tic locking tie and cut off the
tie end.
î
Pass the cylinder head breather
hose along the right side of the
oil tank breather hose.
é
Fasten the sub wire harness to
the frame with a plastic locking
tie and cut off the tie end.
ï
Fasten the TPS lead (in the
sub wire harness) under the
frame.
Page 130 of 608

2 - 22
SPEC
CABLE ROUTING DIAGRAM
ð
Fasten the TPS lead under the
coupler to the frame with a plas-
tic locking tie.
ñPass the carburetor breather
hose and overflow hose
between the connecting rod and
cross tube (frame).
÷Fasten the neutral switch lead
and oil hose together with a
plastic locking tie and cut off the
tie end.
öFasten the cylinder head
breather hose and neutral switch
lead to the frame with a plastic
locking tie.
¯Fasten the neutral switch lead to
the frame with a plastic band.¸Fasten the cylinder head
breather hose with the hose
holder.
ÎPass the clutch cable through
the cable guide.
åFasten the neutral switch lead
and CDI magneto lead
together with a plastic band.
êPass the clutch cable on the
inside the cylinder head
breather hose.
æPass the cylinder head
breather hose along the inner
side of the radiator pipe.
èPass the radiator breather
hose from the right side of the
frame to the left side, over
radiator pipe 1, along the innerside of radiator hose 4 and
the radiator, and between the
lower engine bracket, crank-
case, oil hose and the frame.
×Pass the clutch cable
between the frame and radia-
tor and over the lower boss on
the radiator.
ãPass the neutral switch lead
and CDI magneto lead over
the middle radiator mounting
boss. Then, pass the decom-
pression cable under the mid-
dle radiator mounting boss
and along the left side of the
neutral switch lead and CDI
magneto lead.