Page 26 of 168

2-2
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINETransmission:
Primary reduction system Gear
Primary reduction ratio 3.368 (64/19)
Final drive Chain
Secondary reduction ratio 3.692 (48/13)
Transmission type Constant mesh, 6-speed
Operation Left foot operation
Gear ratio:
1st 2.385 (31/13)
2nd 1.933 (29/15)
3rd 1.588 (27/17)
4th 1.353 (23/17)
5th 1.200 (24/20)
6th 1.095 (23/21)
Chassis: USA, AUS, ZA, NZ EUROPE, CDN
Frame type Semi double cradle←
Caster angle 25.50 ° 25.60 °
Trail 105 mm (4.1 in) 107 mm (4.2 in)
Tire:
Type With tube
Size (front) 80/100-21 51M
Size (rear) 100/90-19 57M
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)          
Brake:
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 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
Item Standard Limit
Cylinder head:
Combustion chamber volume 8.4 cm
3 (0.296 Imp oz, 0.284 US oz)           ----
Warp limit ---- 0.03 mm 
(0.0012 in) 
     
        
        Page 28 of 168

2-4
MAINTENANCE SPECIFICATIONS
Clutch:
Friction plate thickness 2.9–3.1 mm (0.114–0.122 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 ---- 0.2 mm (0.008 
in)
Clutch spring free length 40.1 mm (1.579 in) 38.1 mm 
(1.500 in)
Quantity 5 ----
Clutch housing thrust clearance 0.15–0.26 mm (0.006–0.010 in) ----
Clutch housing radial clearance 0.01–0.04 mm (0.0006–0.0018 in) ----
Clutch release methodInner push, cam push ----
Transmission:
Main axle deflection limit ---- 0.01 mm 
(0.0004 in)
Drive axle deflection limit ---- 0.01 mm 
(0.0004 in)
Shifter:
Shifting type Cam drum and guide bar ----
Guide bar bending limit  ----  0.05 mm 
(0.0020 in)
Kick starter type: Kick and mesh type ----
Kick clip friction force P=0.8–1.2 kg (1.8–2.6 lb) ----
Air filter oil grade (oiled filter): Foam-air-filter oil or equivalent oil ----
Carburetor: USA, CDN EUROPE AUS, NZ, ZA
Type/Manufacturer TMXχ38SS/
MIKUNI          ←←
I.D. mark 1C37 51 1C36 41←----
Main jet (M.J.) #430←←----
Jet needle-clip position (J.N.) 6BFY43-74-3←←----
Cutaway (C.A.) 4.0←←----
Pilot jet (P.J.) #40 #45←----
Pilot air screw (P.A.S.)  2-1/4←←----
Valve seat size (V.S.) ø3.8 mm (0.15 
in)←←----
Starter jet (G.S.) #80←←----
Fuel level (F.L.) 9.5–10.5 mm 
(0.37–0.41 in)←←----
Reed valve:
Thickness 0.47 mm (0.019 in) ----
Valve stopper height 8.2–8.6 mm (0.323–0.339 in) ----
Valve bending limit ---- 0.2 mm (0.008 
in) Item Standard Limit 
     
        
        Page 29 of 168

2-5
MAINTENANCE SPECIFICATIONS
CHASSISCooling:
Radiator core size:
Width 107.8 mm (4.24 in) ----
Height (left) 240 mm (9.45 in) ----
Height (right) 220 mm (8.66 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure 95–125 kPa (0.95–1.25 kg/cm
2, 13.5–17.8 psi) ----
Radiator capacity (total) 0.56 L (0.49 Imp qt, 0.59 US qt) ----
Water pump:
Type Single-suction centrifugal pump ----
Item Standard Limit
Steering system:
Steering bearing typeTaper roller bearing ----
Front suspension: USA, CDN, ZA, AUS, 
NZEUROPE
Front fork travel 300 mm (11.8 in)←----
Fork spring free length 454 mm (17.9 in)←449 mm (17.7 
in)
Spring rate, STD K=4.1 N/mm (0.418 
kg/mm, 23.4 lb/in)←----
Optional spring Yes←----
Oil capacity 524 cm
3 (18.4 Imp oz, 
17.7 US oz)     526 cm3 (18.5 Imp oz, 
17.8 US oz)          ----
Oil grade Suspension oil "S1"←----
Inner tube outer diameter 48 mm (1.9 in)←----
Front fork top end 5 mm (0.2 in)←----
Rear suspension: USA, CDN, ZA, AUS, 
NZEUROPE
Shock absorber travel 131.5 mm (5.18 in)←----
Spring free length Approx. 265 mm (10.43 
in)←----
Fitting length*----
I.D. mark (Red/1) 258 mm (10.16 in) 252 mm (9.92 in) ----
I.D. mark (Red/2) 264 mm (10.39 in) 258 mm (10.16 in) ----
I.D. mark (Red/3) 255.5 mm (10.06 in) 249.5 mm (9.82 in) ----
Preload length
 1.5–18 mm (0.06–0.71 
in)←----
Spring rate, STD K=46.0 N/mm (4.70 
kg/mm, 263.2 lb/in)←----
Optional spring Yes←----
Enclosed gas pressure 1,000 kPa (10 kg/cm
2, 
142 psi)          ←----
* Spring specification varies according to the differ-
ence in the production lot.Item Standard Limit 
     
        
        Page 31 of 168

2-7
TIGHTENING TORQUES
ELECTRICAL
TIGHTENING TORQUES
ENGINE
△- marked portion shall be checked for torque tightening after break-in or before each race.      
Item Standard Limit
Ignition system:
Ignition timing (B.T.D.C.) 0.48 mm (0.019 in) ----
Advancer type Electrical ----
CDI:
Magneto-model (stator)/Manufacturer 1C3-10/YAMAHA ----
Charging coil 1 resistance (color) 720–1,080 Ωat 20 °C (68 °F) (Green/
White-Black/Red)          ----
Charging coil 2 resistance (color) 44–66 Ωat 20 °C (68 °F) (Black-Green/
Blue)          ----
Pickup coil resistance (color) 248–372 Ωat 20 °C (68 °F) (White/Blue-
White/Red)          ----
CDI unit-model/manufacturer 1C3-10/YAMAHA (USA, CDN)
1SR-00/YAMAHA (EUROPE, AUS, ZA, 
NZ)----
Ignition coil:
Model/manufacturer 1C3-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.24–0.36 Ωat 20 °C (68 °F)          ----
Secondary winding resistance 5.7–8.5 kΩat 20 °C (68 °F)          ----
Spark plug cap:
Resistance 4–6 kΩat 20 °C (68 °F)       ----
ItemThread 
sizeQ'ty Tightening torque Remarks
Spark plug M14S 1 20 Nm (2.0 m•kg, 14 ft•lb)
Cylinder head (nut) M8 5 28 Nm (2.8 m•kg, 20 ft•lb)Copper 
washer
Cylinder head (stud) M8 5 13 Nm (1.3 m•kg, 9.4 ft•lb)
Cylinder (nut) M8 4 30 Nm (3.0 m•kg, 22 ft•lb)
Cylinder (stud) M10 4 13 Nm (1.3 m•kg, 9.4 ft•lb)
Power valve:
Cover M5 4 5 Nm (0.5 m•kg, 3.6 ft•lb) YPVS
Link lever M4 1 4 Nm (0.4 m•kg, 2.9 ft•lb) YPVS
Holder (power valve)  M5 4 8 Nm (0.8 m•kg, 5.8 ft•lb) YPVS
Push rod M5 1 5 Nm (0.5 m•kg, 3.6 ft•lb) YPVS
Thrust plate M5 1 4 Nm (0.4 m•kg, 2.9 ft•lb) YPVS
Governor fork M4 2 5 Nm (0.5 m•kg, 3.6 ft•lb) YPVS
Housing M5 3 4 Nm (0.4 m•kg, 2.9 ft•lb) YPVS
Water pump housing cover  M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)
Coolant drain bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)Copper 
washer
Radiator M6 6 10 Nm (1.0 m•kg, 7.2 ft•lb)
Radiator guard M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) 
     
        
        Page 32 of 168

2-8
TIGHTENING TORQUES
Radiator hose clamp M6 8 2 Nm (0.2 m•kg, 1.4 ft•lb)
Air filter element  M6 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Carburetor joint M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)
Carburetor joint clamp M4 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Air filter joint clamp M4 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
△Air filter case M6 4 8 Nm (0.8 m•kg, 5.8 ft•lb)
Air filter guide clamp M5 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Reed valve M3 6 1 Nm (0.1 m•kg, 0.7 ft•lb)
Throttle cable adjust bolt and locknut M8 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Throttle cable M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Crankcase M6 12 14 Nm (1.4 m•kg, 10 ft•lb)
Right crankcase cover M6 8 10 Nm (1.0 m•kg, 7.2 ft•lb)
Left crankcase cover M6 4 5 Nm (0.5 m•kg, 3.6 ft•lb)
Drive chain sprocket cover M6 2 5 Nm (0.5 m•kg, 3.6 ft•lb)
Bearing plate cover M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)
Holder M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil check bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)Copper 
washer
Oil drain bolt M10 1 20 Nm (2.0 m•kg, 14 ft•lb)Copper 
washer
Kickstarter crank M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Clutch cover M6 6 10 Nm (1.0 m•kg, 7.2 ft•lb)
Primary drive gear M8 1 48 Nm (4.8 m•kg, 35 ft•lb)
Clutch boss M16 1 80 Nm (8.0 m•kg, 58 ft•lb) Lock washer
Clutch spring M6 5 10 Nm (1.0 m•kg, 7.2 ft•lb)
Clutch cable adjust bolt and locknutM6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Drive sprocket M18 1 75 Nm (7.5 m•kg, 54 ft•lb) Lock washer
Shift pedal M6 1 12 Nm (1.2 m•kg, 8.7 ft•lb)
Bearing plate cover (shift cam) M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Shift guide M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Stopper lever M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Segment M8 1 30 Nm (3.0 m•kg, 22 ft•lb)
△Exhaust pipe M6 2 12 Nm (1.2 m•kg, 8.7 ft•lb)
△Exhaust pipe stay (front) M6 1 12 Nm (1.2 m•kg, 8.7 ft•lb)
△Exhaust pipe stay (rear) M6 1 12 Nm (1.2 m•kg, 8.7 ft•lb)
Silencer:
△Silencer and frame M6 2 12 Nm (1.2 m•kg, 8.7 ft•lb)
Fiber M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)ItemThread 
sizeQ'ty Tightening torque Remarks 
     
        
        Page 35 of 168
2-11
TIGHTENING TORQUES
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering 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).
ELECTRICAL △Rear fender (front) M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
△Rear fender (rear) M6 2 12 Nm (1.2 m•kg, 8.7 ft•lb)
△Side cover M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)
Seat M8 2 19 Nm (1.9 m•kg, 13 ft•lb)
△Number plate M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)ItemThread 
sizeQ'ty Tightening torque Remarks
ItemThread 
sizeQ'ty Tightening torque Remarks 
Stator M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)
Rotor M12 1 56 Nm (5.6 m•kg, 40 ft•lb)
Ignition coil M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) 
     
        
        Page 39 of 168

2-14
CABLE ROUTING DIAGRAM
D. Install the ignition coil, side core 
and ground lead together to the 
frame. Take care to fasten the 
ground lead so that its terminal 
is within the indicated range.
E. Clamp the throttle cable and 
high tension cord to the frame.
F. Clamp the clutch cable to the left 
engine bracket. Clamp the 
clutch cable below the position-
ing grommet.
G. Pass the air vent hose back of 
the throttle cable.
H. Pass the air vent hose, overflow 
hose and crankcase breather 
hose between the frame and 
connecting rod.
I. Pass the radiator breather hose 
and YPVS breather hose out-
side the engine bracket and in-
side the down tube. Then pass 
the radiator breather hose inside 
the YPVS breather hose.
J. Clamp the CDI magneto lead, 
radiator breather hose and 
YPVS breather hose to the 
frame.
K. Clamp to the frame the CDI 
magneto lead and radiator 
breather hose. Take care to 
clamp them above the projection 
on the frame.
L. Locate the clamp ends in the ar-
rowed range.
M. Direct the clip with its finger grip 
facing forward.
N. Tighten the clamp with its bolt 
head facing the left side of the 
chassis (on both sides of the 
carburetor joint and the air filter 
joint).
O. Pass the air vent hose, overflow 
hose and crankcase breather 
hose so that they do not contact 
the rear shock absorber.
P. Bring the connector cover into 
contact with the coupler. 
     
        
        Page 40 of 168
2-15
CABLE ROUTING DIAGRAM
1. High tension cord
2. Engine stop switch lead
3. Ignition coil lead
4. Clamp
5. CDI unit
6. CDI unit band
7. Radiator breather hose
8. CDI magneto lead
9. Connector cover
10. Throttle cable
11. Clutch cable12. CDI unit stay
A. Pass the high tension cord to the 
left of the radiator hose.
B. Using a plastic locking tie, clamp 
the engine stop switch lead, igni-
tion coil lead and CDI magneto 
lead together with the clamp 
ends backward and then cut off 
the tie end.C. Clamp to the frame the throttle 
cable, clutch cable, ignition coil 
lead and engine stop switch 
lead. In so doing, clamp the igni-
tion coil lead and engine stop 
switch lead at their protecting 
tubes. Tighten the clamp so that 
the engine stop switch lead is 
not pulled when the handlebar is 
turned to the right and left.