Page 105 of 912

MAINTENANCE SPECIFICATIONS
2 - 12
SPEC
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN EUROPE AUS, NZ, ZA
Front fork travel 300 mm (11.8 in)←←
Fork spring free length 460 mm (18.1 in)←←
Spring rate, STD K = 4.4 N/mm
(0.449 kg/mm,
25.1 lb/in)←←
Optional spring/spacer Yes←←
Oil capacity 648 cm
3
(22.8 Imp oz,
21.9 US oz) ←←
Oil level 132 mm (5.20 in)←←
(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)95 ~ 150 mm
(3.74 ~ 5.91 in)←←
Oil grade Suspension oil
“S1”←←
Inner tube outer diameter 48 mm (1.89 in)←←
Front fork top end 5 mm (0.20 in)←←
Rear suspension: USA, CDN EUROPE AUS, NZ, ZA
Shock absorber travel 130 mm (5.12 in)← ←
Spring free length260 mm (10.24 in)← ←
Fitting length 249 mm (9.80 in) 248.5 mm (9.78 in) 245.0 mm (9.65 in)
238.5 ~ 258.5 mm
(9.39 ~ 10.18 in)← ←
Spring rate, STD K = 52.0 N/mm
(5.30 kg/mm,
296.8 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)
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MAINTENANCE SPECIFICATIONS
2 - 13
SPEC
Wheel: USA, CDN, ZA EUROPE, AUS, NZ
Front wheel type Spoke wheel← ----
Rear wheel type Spoke wheel← ----
Front rim size/material 21 × 1.60/Aluminum← ----
Rear rim size/material 18 × 1.85/Aluminum 18 × 2.15/Aluminum ----
Rim runout limit:
Radial ---- ---- 2.0 mm
(0.08 in)
Lateral ---- ---- 2.0 mm
(0.08 in)
Drive chain:
Type/manufacturer DID520VM/DAIDO ----
Number of links 113 links + joint ----
Chain slack 48 ~ 58 mm (1.9 ~ 2.3 in) ----
Chain length (15 links) ---- 239.3 mm
(9.42 in)
Front disc brake:
Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in)
250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in)
245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ---- 0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height above footrest top)10 mm (0.39 in) ----
Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit
Page 107 of 912

MAINTENANCE SPECIFICATIONS
2 - 14
SPEC
NOTE:
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m kg, 27 ft lb) by using the steer-
ing nut wrench, then loosen the steering ring nut one turn.
2. Retighten the steering ring nut 7 Nm (0.7 m kg, 5.1 ft lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Upper bracket and outer tube M8 × 1.25 4 21 2.1 15
Lower bracket and outer tube M8 × 1.25 4 21 2.1 15
Upper bracket and steering stem M24 × 1.0 1 145 14.5 105
Handlebar upper holder and handlebar lower
holderM8 × 1.25 4 28 2.8 20
Handlebar lower holder and upper bracket M10 × 1.25 2 34 3.4 24
Steering stem and steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and front fork cap bolt M51 × 1.5 2 30 3.0 22
Front fork and base valve M30 × 1.0 2 55 5.5 40
Front fork cap bolt and damper rod M12 × 1.25 2 29 2.9 21
Front fork bleed screw and front fork cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and front fork protector M6 × 1.0 6 7 0.7 5.1
Front fork protector and brake hose holder M6 × 1.0 2 7 0.7 5.1
Throttle grip cap M5 × 0.8 2 4 0.4 2.9
Front brake master cylinder M6 × 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 × 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Front brake hose guide and front brake hose
guide bracketM5 × 0.8 1 4 0.4 2.9
Front brake hose guide and lower bracket M6 × 1.0 1 4 0.4 2.9
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting nut M6 × 1.0 1 4 0.4 2.9
Hot starter lever holder M5 × 0.8 2 4 0.4 2.9
Hot starter lever mounting nut M5 × 0.8 1 2 0.2 1.4
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Front brake hose union bolt M10 × 1.25 2 30 3.0 22
Front brake caliper M8 × 1.25 2 23 2.3 17
Front brake caliper and brake hose holder M6 × 1.0 1 10 1.0 7.2
Pad pin plug M10 × 1.0 2 3 0.3 2.2
Front brake caliper and pad pin M10 × 1.0 1 18 1.8 13
Rear brake caliper and pad pin M10 × 1.0 1 18 1.8 13
Brake caliper and bleed screw M8 × 1.25 2 6 0.6 4.3
Front wheel axle and axle nut M16 × 1.5 1 90 9.0 65
Front wheel axle holder M8 × 1.25 4 21 2.1 15
Front brake disc M6 × 1.0 6 12 1.2 8.7
Rear brake disc M6 × 1.0 6 14 1.4 10
Brake pedal M8 × 1.25 1 26 2.6 19
Rear brake master cylinder M6 × 1.0 2 10 1.0 7.2
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt M10 × 1.25 2 30 3.0 22
Rear wheel axle and axle nut M20 × 1.5 1 125 12.5 90
Page 108 of 912

MAINTENANCE SPECIFICATIONS
2 - 15
SPEC
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Nipple (spoke)—72 3 0.3 2.2
Rear wheel sprocket M8 × 1.25 6 50 5.0 36
Rear brake disc cover M6 × 1.0 2 10 1.0 7.2
Rear brake caliper protector M6 × 1.0 2 7 0.7 5.1
Drive chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13
Engine mounting:
Engine and engine bracket (front) M10 × 1.25 1 53 5.3 38
Engine and frame (lower) M10 × 1.25 1 53 5.3 38
Upper engine bracket and frame M8 × 1.25 4 34 3.4 24
Lower engine bracket and frame M8 × 1.25 4 34 3.4 24
Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
Engine guard M6 × 1.0 3 7 0.7 5.1
Regulator M6 × 1.0 2 7 0.7 5.1
Pivot shaft and nut M16 × 1.5 1 85 8.5 61
Relay arm and swingarm M14 × 1.5 1 70 7.0 50
Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
Connecting rod and frame M14 × 1.5 1 80 8.0 58
Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
Rear frame (upper) M8 × 1.25 1 38 3.8 27
Rear frame (lower) M8 × 1.25 2 32 3.2 23
Swingarm and brake hose holder M5 × 0.8 4 2 0.2 1.4
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Upper drive chain tensioner M8 × 1.25 1 16 1.6 11
Lower drive chain tensioner M8 × 1.25 1 16 1.6 11
Drive chain support M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
Fuel tank M6 × 1.0 2 9 0.9 6.5
Fuel cock M6 × 1.0 2 4 0.4 2.9
Seat set bracket and fuel tank M6 × 1.0 1 7 0.7 5.1
Fuel tank bracket and fuel tank M6 × 1.0 4 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
Air scoop and radiator guard (lower) M6 × 1.0 2 6 0.6 4.3
Front fender M6 × 1.0 4 7 0.7 5.1
Rear fender (front) M6 × 1.0 2 7 0.7 5.1
Rear fender (rear) M6 × 1.0 2 11 1.1 8.0
Side cover M6 × 1.0 2 7 0.7 5.1
Seat M8 × 1.25 2 23 2.3 17
Multi-function display bracket and upper
bracketM6 × 1.0 2 7 0.7 5.1
Multi-function display M5 × 0.8 2 4 0.4 2.9
Plate 1 and front fork protector M5 × 0.8 2 4 0.4 2.9
Plate 2 and front fork protector—2 0.5 0.05 0.36
Page 109 of 912
MAINTENANCE SPECIFICATIONS
2 - 16
SPEC
NOTE:
- marked portion shall be checked for torque tightening after break-in. Speed sensor lead holder and lower bracket M6 × 1.0 1 13 1.3 9.4
Headlight body and headlight unit—210.10.7
Headlight (left and right) M6 × 1.0 2 7 0.7 5.1
Taillight—310.10.7
Taillight lead clamp and rear fender—3 0.5 0.05 0.36
Catch tank (upper) M6 × 1.0 1 16 1.6 11
Catch tank (lower) M6 × 1.0 1 7 0.7 5.1
Footrest bracket and frame M10 × 1.25 4 55 5.5 40
Sidestand M10 × 1.25 1 25 2.5 18 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Page 110 of 912

MAINTENANCE SPECIFICATIONS
2 - 17
SPEC
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Pickup coil resistance (color) 248 ~ 372 Ω at 20°C (68 °F)
(White – Red)----
CDI unit-model/manufacturer 5UM-E0/YAMAHA (For USA) ----
5UM-F0/YAMAHA (Except for USA) ----
Ignition coil:
Model/manufacturer 5UL-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.08 ~ 0.10 Ω at 20 °C (68 °F) ----
Secondary coil resistance 4.6 ~ 6.8 kΩ at 20 °C (68 °F) ----
Charging system:
System type AC magneto ----
Model (stator)/manufacturer 5UM 20/YAMAHA ----
Normal output 14 V/120 W at 5,000 r/min ----
Charging coil resistance (color) 0.288 ~ 0.432 Ω at 20 °C (68 °F)
(White – Ground)----
Lighting coil resistance (color) 0.224 ~ 0.336 Ω at 20 °C (68 °F)
(Yellow – Ground)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacture SH770AA/SHINDENGEN ----
Regulated voltage (AC) 12.5 ~ 13.5 V ----
Regulated voltage (DC) 14.0 ~ 15.0 V ----
Rectifier capacity (AC) 12 A ----
Rectifier capacity (DC) 8 A ----
Electric starting system:
Type Constant mesh ----
Starter motor:
Model/manufacturer 5UM01/YAMAHA ----
Operation voltage 12 V ----
Output 0.35 kW ----
Armature coil resistance 0.0189 ~ 0.0231 Ω at 20 °C (68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm (0.14 in)
Brush quantity 2 pcs. ----
Spring force 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)----
Commutator diameter 17.6 mm (0.69 in) 16.6 mm (0.65 in)
Mica undercut (depth) 1.5 mm (0.06 in) ----
Page 111 of 912
MAINTENANCE SPECIFICATIONS
2 - 18
SPEC
NOTE:
Tighten the rotor nut to 65 Nm (6.5 m kg, 47 ft lb), loosen and retighten the rotor nut to 65 Nm
(6.5 m kg, 47 ft lb). Starter relay:
Model/manufacturer 2768090-A/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 °C (68 °F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221 M06/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51 Ω at 20 °C (68 °F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M5 × 0.8 2 7 0.7 5.1
Holder (AC magneto lead) M5 × 0.8 2 7 0.7 5.1
Rotor M12 × 1.25 1 Refer to NOTE.
Neutral switch M5 × 0.8 2 4 0.4 2.9
Starter motor M6 × 1.0 2 10 1.0 7.2
Starter relay terminal M6 × 1.0 2 4 0.4 2.9
Negative lead and cylinder head M6 × 1.0 1 10 1.0 7.2
Pickup coil M6 × 1.0 2 10 1.0 7.2 Item Standard Limit
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2 - 19
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS
SPEC
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm mkg ftlb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3 meter
10-2 meterLength
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg
× m/sec
2 Force
Nm
m kgNewton meter
Meter kilogramN
× m
m
× kgTorque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3 Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute—Engine speed