Page 34 of 224
2-7
MAINTENANCE SPECIFICATIONS
Side clearance0.020–0.055 mm (0.0008–0.0022 in) 0.12 mm (0.005
in)
Oil ring:
Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in)----
End gap (installed) 0.10–0.40 mm (0.004–0.016 in)----
Crankshaft: Crank width "A" 55.95–56.00 mm (2.203–2.205 in) ----
Runout limit "C" 0.03 mm (0.0012 in)0.05 mm (0.002
in)
Big end side clearance "D" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02
in)
Small end free play "F" 0.4–1.0 mm (0.02–0.04 in)2.0 mm (0.08
in)
Clutch: Friction plate thickness 2.9–3.1 mm (0.114–0.122 in)2.7 mm (0.106
in)
Quantity 9----
Clutch plate thickness 1.1–1.3 mm (0.043–0.051 in)----
Quantity 8----
Warp limit ----0.1 mm (0.004
in)
Clutch spring free length 37.0 mm (1.46 in)36.0 mm (1.42
in)
Quantity 5----
Clutch housing thrust clearance 0.10–0.35 mm (0.0039–0.0138 in) ----
Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in) ----
Clutch release method Inner push, cam push----
Shifter: Shifter type Cam drum and guide bar----
Guide bar bending limi t ---- 0.05 mm (0.002
in)
Kickstarter: Type Kick and ratchet type----
Item
StandardLimit
Page 35 of 224
2-8
MAINTENANCE SPECIFICATIONS
Carburetor:USA, CDN, ZA,
AUS, NZ EUROPE
Type/manufacturer FCR-MX37/KEIHIN← ----
I. D. mark 5UME E05UML L0----
Main jet (M.J) #170#160----
Main air jet (M.A.J) #115← ----
Jet needle (J.N) NJRUNNGU----
Cutaway (C.A) 1.5←----
Pilot jet (P.J) #42#45 ----
Pilot air jet (P.A.J) #70← ----
Pilot outlet (P.O) ø0.9←----
Bypass (B.P) ø1.0←----
Valve seat size (V.S) ø3.8←----
Starter jet (G.S) #68← ----
Leak jet (Acc.P) #70← ----
Float height (F.H) 8 mm (0.31 in)← ----
Engine idle speed 1,750–1,950 r/min← ----
Intake vacuum 31.3–36.7 kPa
(235–275 mmHg,
9.25–10.83 inHg) ←
----
Hot starter lever free play 3–6 mm (0.12–0.24
in) ←
----
Lubrication system: Oil filter type Paper type----
Oil pump type Trochoid type----
Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008
in)
Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009
in)
Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.17 mm
(0.0067 in)
Cooling: Radiator core sizeWidth 120.2 mm (4.73 in)----
Height 240 mm (9.45 in)----
Thickness 22 mm (0.87 in)----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi)----
Radiator capacity (total) 0.54 L (0.48 Imp qt, 0.57 US qt)----
Water pump Type Single-suction centrifugal pump----
Item
StandardLimit
Page 36 of 224
2-9
MAINTENANCE SPECIFICATIONS
CHASSISItem Standard Limit
Steering system: Steering bearing type Taper roller bearing ----
Front suspension: 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 = 4.4 N/mm (0.449 kg/mm, 25.1 lb/in)----
Optional spring/spacer Yes----
Oil capacity 648 cm
3 (22.8 lmp oz, 21.9 US oz)----
Oil level 132 mm (5.20 in)----
(From top of outer tube with inner
tube and damper rod fully compressed without
spring.) 95–150 mm (3.74–5.91 in)
----
Oil grade Suspension oil "S1"----
Inner tube outer diamet er 48 mm (1.89 in) ----
Front fork top end 5 mm (0.20 in)----
Rear suspension: USA, CDN AUS, NZ, ZA EUROPE
Shock absorber travel 130 mm (5.12
in) ←←----
Spring free length 260 mm (10.24
in) ←←----
Fitting length 249 mm (9.80
in) 245.0 mm (9.65
in)248.5 mm (9.78
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 limitEnd ---- 1.0 mm (0.04 in)
Wheel: USA, CDN, ZA AUS, NZ, EUROPE
Front wheel type Spoke wheel←----
Rear wheel type Spoke wheel←----
Front rim size/material 21 × 1.60/Aluminum←----
Rear rim size/mater ial 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)
Page 37 of 224
2-10
MAINTENANCE SPECIFICATIONS
ELECTRICALDrive 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
StandardLimit
Item StandardLimit
Ignition system: Advancer type Electrical----
CDI: USA, CDN, ZA,
AUS, NZ EUROPE
Pickup coil resistance (color) 248–372 Ωat 20 °C
(68 °F) (White–Red) ←
----
CDI unit-model/manufacturer 5UM-F0/YAMAHA 5UM-L0/YAMAHA ----
Ignition coil: Model/manufacturer 5UL-10/DENSO----
Minimum spark gap 6 mm (0.24 in)----
Primary coil resistance 0.08–0.10 Ωat 20 °C (68 °F) ----
Secondary coil resistance 4.6–6.8 kΩat 20 °C (68 °F) ----
Charging system: System type AC magneto----
Model (stator)/manufacturer 5UM 30/YAMAHA----
Page 56 of 224
3-1
MAINTENANCE INTERVALS
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maint enance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If
you are a doubt as to what intervals to follow in maintaini ng and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break- in Every
race
Every third
(or 500
km) Every
fifth (or 1,000
km)
As re-
quired Remarks
ENGINE OIL Replace ●●
VALVES Check the valve clearances ●● The engine must be cold.
Inspect ●Check the valve seats and valve
stems for wear.
Replace ●
VALVE SPRINGS Inspect ●Check the free length and the tilt.
Replace ●
VALVE LIFTERS Inspect ●Check for scratches and wear.
Replace ●
CAMSHAFTS Inspect the camshaft surface.
Inspect ●Inspect the decompression system.
Replace ●
CAMSHAFT SPROCKETS Inspect ●Check for wear on the teeth and for
damage.
Replace ●
PISTON Inspect ●●Inspect crack.
Clean ●Inspect carbon deposits and eliminate
them.
Replace ●
PISTON RING Inspect ●Check ring end gap.
Replace ●●
PISTON PIN Inspect ●
Replace ●
CYLINDER HEAD Inspect carbon deposits and eliminate
them.
Inspect and clean ●Change gasket.
CYLINDER Inspect and clean ●Inspect score marks.
Replace ●Inspect wear.
Page 57 of 224
3-2
MAINTENANCE INTERVALS
CLUTCHInspect and adjust ●● Inspect housing, friction plate, clutch
plate and spring.
Replace ●
TRANSMISSION Inspect ●
Replace bearing ●
SHIFT FORK, SHIFT CAM,
GUIDE BAR Inspect ●Inspect wear.
ROTOR NUT Retighten ●●
MUFFLER Inspect and retighten ●●
Clean ●
Replace ●
CRANK Inspect and clean ●●
CARBURETOR Inspect, adjust and clean ●●
AIR INDUCTION SYSTEM Inspect and clean ●● ●●
SPARK PLUG Inspect and clean ●●
Replace ●
DRIVE CHAIN Use chain lube.
Lubricate, slack, alignment ●● Chain slack: 48–58 mm (1.9–2.3 in)
Replace ●
COOLING SYSTEM Check coolant level and leakage ●●
Check radiator cap operation ●
Replace coolant ●Every two years
Inspect hoses ●
OUTSIDE NUTS AND BOLTS Retighten ●● Refer to "STARTING AND BREAK-
IN" section in the CHAPTER 1.
AIR FILTER Clean and lubricate ●● Use foam air-filter oil or equivalent oil.
Replace ●
OIL FILTER Replace ●●
FRAME Clean and inspect ●●
Item
After
break- in Every
race
Every third
(or 500 km) Every
fifth (or
1,000 km)
As re-
quired Remarks
3
Page 58 of 224
3-3
MAINTENANCE INTERVALS
FUEL TANK, COCKClean and inspect ●●
BRAKES Adjust lever position and pedal
height ●●
Lubricate pivot point ●●
Check brake disc surface ●●
Check fluid level and leakage ●●
Retighten brake disc bolts, cali-
per bolts, master cylinder bolts
and union bolts ●●
Replace pads ●
Replace brake fluid ●Every one year
FRONT FORKS Inspect and adjust ●●
Replace oil ●● Suspension oil "S1"
Replace oil seal ●
FRONT FORK OIL SEAL AND
DUST SEAL Clean and lube ●● Lithium base grease
PROTECTOR GUIDE Replace ●
REAR SHOCK ABSORBER Inspect and adjust ●●
Lube ●(After
rain
ride) ●Molybdenum disulfide grease
Retighten ●●
DRIVE CHAIN GUIDE AND
ROLLERS Inspect ●●
SWINGARM Inspect, lube and retighten ●● Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD Inspect, lube and retighten ●● Molybdenum disulfide grease
SIDESTAND Lubricate ●Lithium base grease
STEERING HEAD Inspect free play and retighten ●●
Clean and lube ●Lithium base grease
Replace bearing ●
Item
After
break- in Every
race
Every third
(or 500 km) Every
fifth (or
1,000 km)
As re-
quired Remarks
Page 59 of 224
3-4
MAINTENANCE INTERVALS
TIRE, WHEELSInspect air pressure, wheel run-
out, tire wear and spoke loose-
ness ●●
Retighten sprocket bolt ●●
Inspect bearings ●
Replace bearings ●
Lubricate ●Lithium base grease
THROTTLE, CONTROL CABLE Check routing and connection ●●
Lubricate ●● Yamaha cable lube or SAE 10W-30
motor oil
HOT STARTER, CLUTCH LEVER Inspect free play ●
BATTERY Check terminal for looseness
and corrosion ●
Item
After
break- in Every
race
Every third
(or 500 km) Every
fifth (or
1,000 km)
As re-
quired Remarks
