2-2
GENERAL SPECIFICATIONS
Oil capacity:Engine oilPeriodic oil change 1.1 L (0.97 Imp qt, 1.16 US qt)
With oil filter replacement 1.2 L (1.06 Imp qt, 1.27 US qt)
Total amount 1.4 L (1.23 Imp qt, 1.48 US qt)
Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt)
Air filter: Wet type element
Fuel: Type Premium unleaded gasoline only with a research octane
number of 95 or higher.
Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal)
Reserve 1.1 L (0.24 Imp gal, 0.29 US gal)
Carburetor: Type FCR-MX37
Manufacturer KEIHIN
Spark plug: Type/manufacturer CR9E/NGK (resistance type)
Gap 0.7–0.8 mm (0.028–0.031 in)
Clutch type: Wet, multiple-disc
Transmission: USA, CDN, ZA, AUS, NZEUROPE
Primary reduction system Gear←
Primary reduction ratio 57/17 (3.353)←
Secondary reduction system Chain drive←
Secondary reduction ratio 50/13 (3.846)47/14 (3.357)
Transmission type Constant mesh, 5-speed←
Operation Left foot operation←
Gear ratio: 1st 31/13 (2.385)←
2nd 28/16 (1.750)←
3rd 23/17 (1.353)←
4th 23/21 (1.095)←
5th 17/19 (0.895)←
Chassis: USA, CDN, ZA AUS, NZ EUROPE
Frame type Semi double cra-
dle ←←
Caster angle 27.0 °26.6 ° 26.5 °
Trail 115 mm (4.53 in) 114 mm (4.49 in) 113 mm (4.45 in)
Tire: Type With tube
Size (front) 80/100-21 51M (For USA, CDN and ZA)
90/90-21 54R (For EUROPE, AUS and NZ)
Size (rear) 100/100-18 59M (For USA, CDN and ZA)
130/90-18 69R (For EUROPE, AUS and NZ)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
2
2-3
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINEBrake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension: Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber: Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel: Front wheel travel 300 mm (11.8 in)
Rear wheel travel 310 mm (12.2 in)
Electrical: Ignition system CDI
Generator system AC magneto
Battery type YTZ7S (F)
Battery voltage/capacity 12V/6 AH
Specific gravity 1.310
Headlight type: Quartz bulb (halogen)
Bulb wattage × quantity: Headlight 12 V 35/36.5 W × 1
Taillight 12 V 1.6/0.3 W × 1
ItemStandardLimit
Cylinder head: Warp limit ----0.05 mm (0.002
in)
Cylinder: Bore size 77.00–77.01 mm (3.0315–3.0319 in) ----
Out of round limit ----0.05 mm (0.002
in)
Camshaft: Drive method Chain drive (Left)----
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ----
Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ----
Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003
in)
2-8
MAINTENANCE SPECIFICATIONS
Shifter:Shifter type Cam drum and guide bar----
Guide bar bending limit ----0.05 mm (0.002
in)
Kickstarter: Type Kick and ratchet type----
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
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)----
tube and damper rod fully compressed 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 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)----
Preload length
(0.06–0.51 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/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)
2-11
MAINTENANCE SPECIFICATIONS
Charging system:System type AC magneto----
Model (stator)/manufacturer 5UM 30/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) ----
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 M38/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----
Item
StandardLimit
7-19
LIGHTING SYSTEM
CHECKING THE TAILLIGHT
(LEDs)
1. Disconnect the taillight coupler.
2. Connect two jumper leads "1" from the battery terminals to the
respective coupler terminal as
shown.
3. Check: • LED (for proper operation)Does not light →Replace the tail-
light assembly.
• A wire that is used as a jumper lead must have at least the same
capacity of the battery lead, oth-
erwise the jumper lead may burn.
• This check is likely to produce sparks, therefore, make sure no
flammable gas or fluid is in the
vicinity.
CHECKING THE AC MAGNETO
1. Inspect:
• Lighting coil resistanceOut of specification →Replace. CHECKING THE RECTIFIER/
REGULATOR
1. Connect the battery leads.
2. Start the engine.
3. Turn on the headlight and taillight
by turning on the light switch.
4. Inspect:
• Out-put voltageOut of specification →Replace
rectifier/regulator.
Battery (+) terminal
→Blue lead
"2"
Battery (-) terminal →Black lead
"3"
Tester (+) lead →Yellow lead "1"
Tester (-) lead →Ground "2"
Lighting
coil resis- tance Tester se-
lector posi- tion
0.224–0.336 Ω at 20 °C
(68 °F) Ω × 1
Tester (+) lead
→Yellow lead "1"
Tester (-) lead →Black lead "2"
Out-put voltage Tester se-
lector posi- tion
12.5–13.5 V at 5,000 r/ min ACV-20