Page 47 of 457
2-19
TIGHTENING TORQUESSPEC
Use a lock
washer
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmmkgftlbRemarks
Spark plugs—M104131.39.4
Cylinder headNutM1010See NOTE 1
BoltM62121.28.7
Camshaft capsBoltM628101.07.2
Cylinder head coverBoltM66121.28.7
Cylinder head (exhaust pipe)Stud boltM88151.511
Air indication system capBoltM64101.07.2
Camshaft sprocketsBoltM74242.417
Cylinder head and throttle bodyClampM5430.32.2
Connecting rod capsBoltM8820+1502.0+15014+150
Generator rotorBoltM101606.043
Timing chain tensionerBoltM62101.07.2
Water pump outlet pipeBoltM61101.07.2
Water pump inlet pipeBoltM61101.07.2
(water pump side)
Water pump inlet pipe (front side)BoltM61101.07.2
Oil / water pump assembly
sprocketBoltM61151.511
Water pumpBoltM62121.28.7
Thermostat coverNutM62101.07.2
Thermostat inlet pipeBoltM61101.07.2
Oil coolerBoltM201636.346
Engine oil drain boltBoltM141434.331
Oil pipeBoltM62101.07.2
Oil strainerBoltM63101.07.2
Oil delivery pipeBoltM63101.07.2
Oil filter union boltBoltM201707.051
Oil filter—M201171.712
Oil panBoltM614121.28.7
Oil panBoltM61121.28.7
Air filter case coverScrewM5101.70.171.2
Throttle body and throttle body
jointClampM5430.32.2
Throttle body and funnelBoltM564.20.423.0
Throttle cableNutM614.50.453.3
Throttle cable adjusterBoltM614.50.453.3
Stator coilScrewM63141.410
Generator rotor cover and
bearing housingScrewM63101.07.2
Pull lever coverBoltM62101.07.2
Thermostat assembly stayBoltM62101.07.2
Starter clutch idler gearBoltM61101.07.2
Clutch bossNutM201959.569Stake
Clutch springBoltM66101.07.2
Drive sprocketNutM221858.561
ProCarManuals.com
Page 51 of 457
2-23
TIGHTENING TORQUESSPEC
See NOTE 2 CHASSIS TIGHTENING TORQUES
ItemThreadTighteningRemarksItemsizeNmmkgftlbRemarks
Upper bracket and outer tubeM8262.619
Upper bracket and steering stem nutM2811 311.382
Handlebar and outer tubeM8171.712
Handlebar and upper bracketM6131.39
Steering shaft and ring nutM30181.813See NOTE 1
Outer tube and under bracketM8232.317
Main switch and upper bracketM8262.619
Front brake master cylinder cap stopperM41.20.120.9
Front brake hose union boltsM10303.022
Front brake master cylinder and bracketM6131.39
Meter assembly and front cowling stay—1.30.130.9
Headlight and front cowling stay—0.80.080.6
Front cowling and headlight assembly—1.50.151.1
Cover 7, 8 and frameM650.53.6
Under cowling and engineM650.53.6
Windshield and front cowlingM50.40.040.3
Duct and console panelM51.30.130.9
End grip and handlebarM640.42.9
Horn bracket and under bracketM640.42.9
Coolant reservoir tank and frameM650.53.6
Engine mount front (left and right)M10454.533
Engine mount rear upperM10515.137
Engine mount rear underM10515.137
Engine mount rear adjust boltM1670.75.1
Catalyst pipe stay and frameM10444.432
Clutch cable lock nut (engine side)M870.75.1
Main frame and rear frameM10414.130
Throttle cable adjust nut (throttle body side)M650.53.6
Cover 2 and plate—0.80.080.6
Pivot shaft and nutM1810510.576
Connecting rod and frameM10444.432
Relay arm and connecting rodM10444.432
Relay arm and swingarmM10444.432
Rear shock absorber and relay armM10444.432
Rear shock absorber and upper bracketM10444.432
Upper bracket and frameM14929.267
Seal guardM670.75.1
Drive chain caseM670.75.1
Chain puller adjust nutM8161.612
Fuel tank and fuel pump assemblyM540.42.9
Fuel tank stay (front side) and frameM670.75.1
Fuel tank and fuel tank stay (front side)M670.75.1
Fuel tank stay (rear side) and rear frameM670.75.1
Side cover and fuel tankM50.40.040.3
Rider seat and frameM670.75.1
Seat lock plate and rear frameM6101.07
Side cover (rear side) and frameM540.42.9
ProCarManuals.com
Page 52 of 457
2-24
TIGHTENING TORQUESSPEC
NOTE 1:
NOTE 2:
NOTE 3:
ItemThreadTighteningRemarksItemsizeNmmkgftlbRemarks
Battery box and frameM670.75.1
Atmospheric pressure sensor and battery box—0.70.070.5
Lean angle cut-off switch and battery box—20.21.4
Foot rest bracket (front) and frameM8282.820
Foot rest bracket (rear) and frameM8282.820
Rear brake master cylinder and foot rest bracketM6181.813
Rear brake hose union boltM10303.022
Sidestand bracket and frameM10636.346
Front wheel axle shaft and boltM14919.166
Rear wheel axle nutM2415015.0109
Front brake caliper and front forkM10353.525
Front brake disc and front wheelM6181.813
Rear brake disc and rear wheelM6303.022
Rear wheel sprocket and drive hubM1010010.072
Brake caliper bleed screwM860.64.3
Front wheel axle pinch boltM8202.014See NOTE 3
1. First, tighten the ring nut to approximately 52 Nm (5.2 mkg, 38 ftlb) with a torque wrench, then
loosen the ring nut completely.
2. Retighten the lower ring nut to specification.
Refer to “INSTALLING THE ENGINE” in chapter 5.
1. Insert the front wheel axle from the right side
and tighten it with the flange bolt from the left
side to 91 Nm (9.1 mkg, 65.8 ftlb).
2. In the order from the pinch bolt
2 pinch
bolt
1 pinch bolt 2, tighten each bolt to
20 Nm (2.0 mkg, 14 ftlb) without perform-
ing temporary tightening.
3. Check that the end face of the axle head and
the end face of the fork side are flush-
mounted. If they are out of alignment, make
sure to fit them by adding the external force
by hand or with a plastic hammer, etc.
If the end face of the axle is not parallel to the
end face of the fork, align them so that one
point of the axle circumference is positioned
on the end face of the fork.
At this stage, it can be accepted if the end
face of the axle becomes partially concave
to the end face of the fork.
4. In the order from the pinch bolt
4 pinch
bolt
3 pinch bolt 4, tighten each bolt to
20 Nm (2.0 mkg, 14 ftlb) without perform-
ing temporary tightening.
ProCarManuals.com
Page 53 of 457
2-25
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point
Lubricant
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil pump housing
Oil strainer
Clutch (pull rod)
Oil / water pump drive sprocket and washer
Clutch (thrust plate)
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum
Shift forks and shift fork guide bars
Shift shaft
Shift shaft boss
Cylinder head cover mating surfaceYamaha bond
No.1215
Crankcase mating surfaceYamaha bond
No.1215
Clutch cover (crankcase mating surface)Yamaha bond
No.1215
Generator rotor cover (crankcase mating surface)Yamaha bond
No.1215
Pickup rotor coverYamaha bond
No.1215
ProCarManuals.com
Page 54 of 457
2-26
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00032
CHASSIS
Lubrication point
Lubricant
Steering bearings and bearing races (upper and lower)
Throttle grip inner surface
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Engine mount bolts (rear upper and lower)
Relay arm, connecting rod and rear shock absorber collar
Pivot shaft
Swingarm pivot bearing
Swingarm head pipe end, oil seal and bush
Oil seal (relay arm, connecting arm and rear shock absorber)
Seat lock assembly moving parts
Sidestand pivoting pint and metal-to-metal moving parts
Link and sidestand switch contact point
Sidestand hook and spring
Shift shaft joint
Front wheel oil seal (right and left)
Front axle shaft
Rear wheel oil seal
Rear wheel drive hub oil seal
Rear wheel drive hub mating surface
ProCarManuals.com
Page 57 of 457
2-29
ENGINE OIL LUBRICATION CHARTSPEC
ENGINE OIL LUBRICATION CHART
ProCarManuals.com
Page 67 of 457
2-39
E Clamp the clamp upper end
along the line of lower end of the
hose clamp assembly. Point the
tip of the clamp (surplus section)
to the front side of the vehicle.
Clutch cable is what the clamp
fastens.
F The clutch cable doesn’t project
outside the water hose and the
cylinder head in the box part in
the figure.
G To the engine
H Clamp behind the bracket 3.17Throttle body lead
A Clamp it after passing between
the frame and radiator stay.
Point the tip of the clamp (exces-
sive part) to the front side of the
vehicle. Fasten the right handle-
bar switch lead with a clamp.
B To the wire harness
C The clutch cable positioning
guide should be above the upper
end of the clamp. Fasten the
clutch cable with a clamp. (Refer
to )
D Position relation between the
clamp and guide.
M
CABLE ROUTINGSPEC
1Wire harness
2Crankshaft position sensor lead
3Heat protector
4Right handlebar switch lead
5Positioning guide
6Rear brake light switch lead
7Coolant reservoir tank
8Speed sensor lead
9Clutch cable
10Radiator
11Oil cooler outlet hose
12Coolant reservoir tank drain
hose
13Breather pipe
14Fuel tank drain hose
15A.C. magneto lead
16Wire harness
ProCarManuals.com
Page 72 of 457
2-44
K Pass the water hose lower side
of the thermostat, and between
the ground lead and the neutral
switch.
L Install the leads so that the en-
gine ground lead is positioned
lower and the battery negative
lead to be upper. Install the pro-
trusion of each lead to be above
the vehicle.
M Route the crankshaft position
sensor lead under the wire har-
ness.
N To the fuel pump
O Clamp the wire harness winding
in and insert it to the frame hole.A Pass the wire harness through
the clamp inserted to the radiator
stay.
B To the headlight lead
C Clamp the lead between three
protrusions of the pipe (the first
and second parts from the ve-
hicle front). Point the tip of the
clamp (excessive part) to the in-
side of the vehicle.
D To the vehicle right side diagram
E To the engine
F Clamp the lead between three
protrusions of the pipe (the in-
side and outside of the vehicle).G Point the tip of the clamp (exces-
sive part) to the inside of the ve-
hicle.
H All hoses and leads should be
routed over the vehicle’s upper
side above the heat protector.
I To the starter motor
J Fasten the wire harness, clank
shaft position sensor lead, rear
brake light switch lead and
speed sensor lead with a clamp.
Then, point the tip of the clamp
(cut the tip of the clamp leaving 2
to 4 mm (0.08 to 0.16 in).) to the
inside of the vehicle.
CABLE ROUTINGSPEC
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