Page 37 of 230
2-7
MAINTENANCE SPECIFICATIONS
Crankshaft:
Crank width "A" 61.95–62.00 mm (2.439–2.441 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)
Balancer:
Balancer drive method Gear ----
Air filter oil grade: Foam-air-filter oil or equivalent oil ----
Clutch:
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) 2.8 mm (0.110
in)
Quantity 8 ----
Clutch plate thickness 1.5–1.7 mm (0.059–0.067 in) ----
Quantity 7 ----
Warp limit ---- 0.1 mm (0.004
in)
Clutch spring free length 50.0 mm (1.97 in) 49.0 mm (1.93
in)
Quantity 6 ----
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 limit ---- 0.05 mm (0.002
in)
Kickstarter:
Type Kick and ratchet type ----
Fuel pump:
Fuel pressure 324 kPa (3.24 kg/cm
2, 46.1 psi) ----
Fuel injector:----
Model/manufacturer 1010/DENSO ----
Throttle body:----
I. D. mark 33D1 00 ----
Manufacturer KEIHIN ----Item Standard Limit
Page 38 of 230
2-8
MAINTENANCE SPECIFICATIONS
Throttle position sensor:----
Throttle position sensor maximum resistance 5 kΩ----
Throttle position sensor variable resistance 0–2 kΩ (full closed) ----
Throttle position sensor input voltage 4–6 V ----
Fuel injection sensor:----
Crankshaft position sensor resistance 248–372 Ω----
Intake air pressure sensor output voltage 3.57–3.71 V at 101.3kPa (1.013 kg/cm
2,
14.41 psi)----
Atmospheric pressure sensor output voltage 3.57–3.71 V at 101.3kPa (1.013 kg/cm
2,
14.41 psi)----
Intake air temperature sensor 5.4–6.6 kΩat 0 °C (32 °F)
290–390 Ωat 80 °C (176 °F)----
Idling condition:----
Engine idle speed 1,900–2,100 r/min ----
Oil temperature 55–65 °C (131–149 °F) ----
Throttle cable free play 3–5 mm (0.12–0.20 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 (0.007
in)
Bypass valve setting pressure 40–80 kPa (0.4–0.8 kg/cm
2, 5.69–11.38
psi)----
Cooling:
Radiator core size
Width 121.4 mm (4.78 in) ----
Height 235 mm (9.25 in) ----
Thickness 28 mm (1.10 in) ----
Radiator cap opening pressure 108–137 kPa (1.08–1.37 kg/cm
2,
15.4–19.5 psi)----
Radiator capacity (total) 0.62 L (0.55 Imp qt, 0.66 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit
Page 39 of 230
2-9
MAINTENANCE SPECIFICATIONS
CHASSIS
Item Standard Limit
Steering system:
Steering bearing typeTaper roller bearing ----
Front suspension: USA, CDN EUROPE, AUS, NZ, ZA
Front fork travel 310 mm (12.2 in)←----
Fork spring free length 470 mm (18.5 in)←465 mm (18.3
in)
Spring rate, STD K = 4.6 N/mm (0.469 kg/
mm, 26.3 lb/in)←----
Optional spring Yes←----
Oil capacity 544 cm
3 (19.1 lmp oz,
18.4 US oz)←----
Oil grade Suspension oil "S1"←----
Inner tube outer diameter 48 mm (1.89 in)←----
Front fork top end Zero mm (Zero in)←----
Rear suspension: USA, CDN EUROPE, AUS, NZ, ZA
Shock absorber travel 132.0 mm (5.20 in)←----
Spring free length 260 mm (10.24 in)←254.8 mm
(10.03 in)
Fitting length 252 mm (9.92 in) 253 mm (9.96 in) ----
Preload length
1.5–18 mm (0.06–0.71
in)←
Spring rate, STD K = 56.0 N/mm (5.7 kg/
mm, 319.2 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)
Wheel:
Front wheel type Spoke wheel ----
Rear wheel typeSpoke wheel ----
Front rim size/material 21 × 1.60/Aluminum ----
Rear rim size/material 19 × 2.15/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08
in)
Lateral ---- 2.0 mm (0.08
in)
Drive chain:
Type/manufacturer DID520DMA2 SDH/DAIDO ----
Number of links 113 links + joint ----
Chain slack 50–60 mm (2.0–2.4 in) ----
Chain length (15 links) ---- 242.9 mm
(9.563 in)
Page 40 of 230
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) ----
33D4 (EUROPE) ----
33D6 (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) ----
Page 57 of 230
3-1
MAINTENANCE INTERVALS
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
• The following schedule is intended as a general guide to maintenance 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 maintaining and lubricating your machine, consult your Yamaha dealer.
• Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies sub-
stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.). Therefore, earlier inspection is
required by reference to the list below..
ItemAfter
break-
inEvery
race
(about
2.5
hours)
Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks
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●●Replace the piston, piston pin, piston
pin clip, and piston ring all as a set.
PISTON RING
Inspect●Check ring end gap.
Replace●●Replace the piston, piston pin, piston
pin clip, and piston ring all as a set.
PISTON PIN
Inspect●
Replace●●Replace the piston, piston pin, piston
pin clip, and piston ring all as a set.
3
Page 58 of 230
3-2
MAINTENANCE INTERVALS
CYLINDER HEAD Inspect carbon deposits and eliminate them.
Inspect and clean ●Change gasket.
CYLINDER Inspect and clean ●Inspect score marks.
Replace ●Inspect wear.
CLUTCH Inspect 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 ●●
EXHAUST PIPE, SILENCER,
PROTECTOR Inspect and retighten ●●
Clean ●
Replace fiver ●●* * When the exhaust sound becomes
louder or when a performance drop is
felt.
CRANK Inspect and clean ●●
THROTTLE BODY Inspect ●
SPARK PLUG Inspect and clean ●●
Replace ●
DRIVE CHAIN Use chain lube. Lubricate, slack, alignment ●● Chain slack: 50–60 mm (2.0–2.4 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.
Item
After
break- in Every
race
(about 2.5
hours)
Every third
(about 7.5
hours) Every
fifth
(about 12.5
hours)
As re-
quired Remarks
Page 59 of 230
3-3
MAINTENANCE INTERVALS
AIR FILTER
Clean and lubricate●●Use foam air-filter oil or equivalent oil.
Replace●
OIL FILTER
Replace●●
ENGINE GUARD
Replace●Breakage
FRAME
Clean and inspect●●
FUEL TANK, FUEL PUMP
inspect●●
FUEL HOSE
Inspect●
Replace●Every four years
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●● ItemAfter
break-
inEvery
race
(about
2.5
hours)
Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks
Page 60 of 230
3-4
MAINTENANCE INTERVALS
SWINGARM
Inspect, lube and retighten●●Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD
Inspect, lube and retighten●●Molybdenum disulfide grease
STEERING HEAD
Inspect free play and retighten●●
Clean and lube●Lithium base grease
Replace bearing●
TIRE, WHEELS
Inspect 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●●Yamaha cable lube or SAE 10W-40
motor oil
Lubricate●● ItemAfter
break-
inEvery
race
(about
2.5
hours)
Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks
