CONTENTS
CHAPTER 1
GENERAL
INFORMATION
LOCATION OF
IMPORTANT LABELS ..... 1-1
DESCRIPTION ................. 1-5
CONSUMER
INFORMATION................. 1-6
FEATURES....................... 1-7
INCLUDED PARTS .......... 1-9
IMPORTANT
INFORMATION................. 1-9
HANDLING THE
ELECTRONIC PARTS ... 1-10
CHECKING OF
CONNECTION ................ 1-10
SPECIAL TOOLS ........... 1-12
CONTROL
FUNCTIONS ................... 1-17
STARTING
AND BREAK-IN.............. 1-17
TORQUE-CHECK
POINTS........................... 1-19
CLEANING
AND STORAGE ............. 1-20
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-3
TIGHTENING
TORQUES ...................... 2-11
LUBRICATION
DIAGRAMS .................... 2-17
CABLE ROUTING
DIAGRAM ....................... 2-18
CHAPTER 3
REGULAR
INSPECTION AND
ADJUSTMENTS
MAINTENANCE
INTERVALS ...................... 3-1
PRE-OPERATION
INSPECTION
AND MAINTENANCE ....... 3-5
ENGINE ............................ 3-6
CHASSIS ........................ 3-14
ELECTRICAL ................. 3-24
CHAPTER 4
ENGINE
SEAT
AND SIDE COVERS ......... 4-1
EXHAUST PIPE
AND SILENCER ............... 4-3
RADIATOR ....................... 4-7
CAMSHAFTS.................. 4-10
CYLINDER HEAD........... 4-15
VALVES AND
VALVE SPRINGS ........... 4-19
CYLINDER
AND PISTON .................. 4-23
CLUTCH ......................... 4-27
OIL FILTER ELEMENT
AND WATER PUMP ....... 4-31
BALANCER .................... 4-35
OIL PUMP ....................... 4-37
KICK SHAFT
AND SHIFT SHAFT ........ 4-40
AC MAGNETO................ 4-45
ENGINE REMOVAL ....... 4-47
CRANKCASE
AND CRANKSHAFT ...... 4-52
TRANSMISSION,
SHIFT CAM
AND SHIFT FORK .......... 4-58
CHAPTER 5
CHASSIS
FRONT WHEEL
AND REAR WHEEL .........5-1
FRONT BRAKE
AND REAR BRAKE..........5-6
FRONT FORK .................5-16
HANDLEBAR..................5-24
STEERING ......................5-28
SWINGARM ....................5-32
REAR
SHOCK ABSORBER ......5-37
CHAPTER 6
FUEL SYSTEM
FUEL TANK ......................6-1
THROTTLE BODY ............6-4
CHAPTER 7
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........7-1
IGNITION SYSTEM...........7-3
THROTTLE POSITION
SENSOR SYSTEM ...........7-6
FUEL INJECTION
SYSTEM............................7-9
FUEL PUMP SYSTEM ....7-35
ELECTRICAL
COMPONENTS...............7-36
CHAPTER 8
TUNING
CHASSIS ..........................8-1
2-10
MAINTENANCE SPECIFICATIONS
ELECTRICALFront 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. 9.52 mm (0.375 in) ----
Caliper cylinder inside dia. 22.65 mm (0.892 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)Zero mm (Zero in) ----
Clutch lever free play (lever end) 7–12 mm (0.28–0.47 in) ----
Throttle grip free play3–5 mm (0.12–0.20 in) ---- Item Standard Limit
Item Standard Limit
Ignition system:
Advancer type Electrical ----
AC magneto:
Magneto-model (stator)/manufacturer 33D00/YAMAHA ----
Stator coil resistance (color) 0.60–0.90 Ωat 20 °C (68 °F)
(White–White)----
Crankshaft position sensor resistance (color) 248–372 Ωat 20 °C (68 °F) (Gray–Black) ----
ECU-model/manufacturer 33D0 (USA, CDN) ----
33D1 (EUROPE) ----
33D3 (AUS, NZ, ZA) ----
Ignition coil:
Model/manufacturer F6T541/MITSUBISHI ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 3.57–4.83 Ωat 20 °C (68 °F) ----
Secondary coil resistance 10.71–14.49 kΩat 20 °C (68 °F) ----
Coolant temperature sensor:
Coolant temperature sensor resistance 2.51–2.78 kΩat 20 °C (68 °F) ----
210–220 kΩat 100 °C (212 °F) ----
