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Tài liệu hướng dẫn sữa chữa Yamaha Nozza FI

52BF8197E0.book Page 6 Wednesday, July 20, 2011 11:01 AM

FEATURES

GEN
INFO

AIRFLOW DIRECTIONS AT DIFFERENT
THROTTLE POSITIONS
1. Throttle valve 1 and throttle valve 2 are closed
(idle).

2. Throttle valve 1 opens a little and throttle valve 2
is closed (low speed).

3. Throttle valve 1 and throttle valve 2 are from
half-open to fully-open (moderate or high
speed).

Cautions:
● 2nd movement screw 1


NOTICE
No adjustment should be made to the 2nd
movement screw.

1-6


52BF8197E0.book Page 7 Wednesday, July 20, 2011 11:01 AM

FEATURES

GEN
INFO

ATOMIZATION EFFECT (IDLE AND LOW
SPEED)
1 Fuel injector
2 By-pass channel (introduction of strong airflows)
3 Mixture of air/fuel (intake)

1. The atomization effects of ordinary FI (coarser
fuel particles)

2. The atomization effects of YMJET-FI (finer fuel
particles)

1-7


52BF8197E0.book Page 8 Wednesday, July 20, 2011 11:01 AM

FEATURES

GEN
INFO

O2 SENSOR SUMMARY
The O2 sensor helps achieve high performance when the catalyst mixes the air and fuel to a measured ratio of
14.7:1. This O2 sensor uses solid state electrolytic oxygen ion conduction to detect the oxygen density. During

operation, the zirconium tube made of solid state electrolytes is placed in the exhaust so that the external part
of the zirconium tube comes into contact with the exhaust, while the internal part comes into contact with the
atmosphere that has a known oxygen density. When the external part and the internal part of the zirconium
tube have a different oxygen density, the oxygen ions generate voltage through the zirconium filter. When the
oxygen density is low (the air-fuel ratio is saturated), the voltage is increased. When the oxygen density is high
(the air-fuel ratio is low), the voltage is lowered. The voltage generated based on the exhaust density is input
into the ECU so it can correct the fuel injection time.

Illustration is for reference only.

1
2
3
4
5

È
É
Ê
Ë
Ì
Í

Inner cover
Outer cover
Zirconium tube
Exhaust
Atmosphere

1-8

Atmosphere
Internal electrode
Zirconium filter
External electrode
Porous ceramic layer
Exhaust


52BF8197E0.book Page 12 Wednesday, July 20, 2011 11:01 AM

SPECIAL TOOLS

GEN
INFO

EAS00270

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the
appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or
improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.

Tool no.
90890-01085
90890-01084

Tool name/Usage

Illustration

Slide hammer bolt (8 mm) 1
Weight 2
(Special tool list : 2-2)
ø8.5

These tools are used when removing the
rocker arm shafts.
90890-01235

Rotor holding tool
This tool is used to hold the A.C.
magneto rotor when removing or
installing the A.C. magneto rotor nut.

90890-01268

Ring nut wrench

This tool is used to loosen and tighten
the steering ring nut.
90890-01311

Tappet adjusting tool

This tool is necessary for adjusting valve
clearance.
90890-01326
90890-01294

T-handle 1
Damper rod holder 2
This tool is used for holding the damper
rod holder when removing or installing
the damper rod holder.

90890-01348

Locknut wrench
This tool is used to loosen and tighten
the clutch carrier locknut of the
secondary sheave.

90890-01189

Flywheel puller

This tool is used for removing the A.C.
magneto rotor.

1-12


52BF8197E0.book Page 13 Wednesday, July 20, 2011 11:01 AM

SPECIAL TOOLS
Tool no.
90890-01184
90890-01186

Tool name/Usage
Fork seal driver weight 1
Fork seal driver attachment (ø27 mm) 2

This tool is used to installing the oil seal.
90890-01384

Oil seal guide

This tool is used to install oil seals.
90890-01403

Steering nut wrench

This tool is used to loosen and tighten
the steering ring nut.
90890-01701

Sheave holder

This tool is used for holding the primary
sheave and secondary sheave.
YMV-SL047-00

Special thickness gauge

This tool is used to measure the valve
clearance.
YMV-SL041-00

Compression gauge

These tools are used to measure the
engine compression.
YMV-SI009-00

Digital tachometer

This tool is needed for detecting engine
rpm.
90890-03141

Timing light

This tool is used for measuring mark at
A.C. magneto rotor.
YMV-SL054-00

Pocket tester

These instruments are invaluable for
checking the electrical system.

1-13

GEN
INFO

Illustration


52BF8197E0.book Page 14 Wednesday, July 20, 2011 11:01 AM

SPECIAL TOOLS
Tool no.
90890-04101

Tool name/Usage
Valve lapper

This tool is used for lapping the valve.
90890-04019
90890-04108

Valve spring compressor
Valve spring compressor attachment
(ø19 mm)
These tools are used when removing or
installing the valve and the valve spring.

90890-04116

Valve guide remover (ø4.5 mm)

This tool is needed to remove and install
the valve guide.
90890-04117

Valve guide installer (ø4.5 mm)

This tool is needed to install the valve
guide.
90890-04099

Valve guide reamer (ø5 mm)

This tool is needed to rebore the new
valve guide.
90890-06754

Ignition checker
This instrument is necessary for
checking the ignition system
components.

90890-85505

Yamaha bond No. 1215
(Three bond No. 1215®)
This sealant (bond) is used for
crankcase mating surface, etc.

90890-03174

Digital circuit tester

This instrument is necessary for
checking the electrical system.
90890-03182

FI diagnostic tool

This tool is used to check the diagnostic.

1-14

GEN
INFO

Illustration


52BF8197E0.book Page 15 Wednesday, July 20, 2011 11:01 AM

SPECIAL TOOLS
Tool no.
90890-01304

Tool name/Usage
Piston pin puller set

This tool is used for removing piston pin.
90890-03153

Pressure guage

This tool is needed to measure fuel
pressure.
90890-03186

Fuel pressure adapter

This tool is needed to measure fuel
pressure.
90890-01135

Crankcase separating tool

This tool is necessary for separating the
crankcase.
90890-01274

Crankshaft installer pot

This tool is necessary for installing the
crankshaft.
90890-01275

Crankshaft installer bolt

This tool is necessary for installing the
crankshaft.
90890-01278

Adapter (M12)

This tool is necessary for installing the
crankshaft.
90890-04156

Crankshaft installer spacer

This tool is necessary for installing the
crankshaft.
YMV-SL059-00

Spring clutch removal

This tool is used for disassembly and
assembly the secondary sheave.

1-15

GEN
INFO

Illustration


52BF8197E0.book Page 16 Wednesday, July 20, 2011 11:01 AM

SPECIAL TOOLS
Tool no.
90890-03182

Tool name/Usage
FI diagnostic tool

1-16

GEN
INFO

Illustration


52BF8197E0.book Page 1 Wednesday, July 20, 2011 11:01 AM

SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................ 2-2
CHASSIS SPECIFICATIONS .......................................................................... 2-7
ELECTRICAL SPECIFICATIONS ................................................................... 2-9
CONVERSION TABLE ..................................................................................2-11
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-11
TIGHTENING TORQUES ..............................................................................2-12
ENGINE ...................................................................................................2-12
CHASSIS .................................................................................................2-14
LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-16
ENGINE ...................................................................................................2-16
CHASSIS .................................................................................................2-17
LUBRICATION DIAGRAMS.......................................................................... 2-18
CABLE ROUTING .........................................................................................2-20


52BF8197E0.book Page 2 Wednesday, July 20, 2011 11:01 AM

SPEC


52BF8197E0.book Page 1 Wednesday, July 20, 2011 11:01 AM

GENERAL SPECIFICATIONS

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and fuel) weight
Dry weight
Maximum load*
* Total weight of rider, passenger, cargo and accessories

XC115S
DR1
1795 mm (70.7 in.)
685 mm (26.97 in.)
1030 mm (40.6 in.)
750 mm (29.5 in.)
1250 mm (49.2 in.)
115 mm (4.53 in.)
1800 mm (70.9 in.)
98 kg (216.1 lb)
93 kg (205.1 lb)
156 kg (343.98 lb)

2-1

SPEC


52BF8197E0.book Page 2 Wednesday, July 20, 2011 11:01 AM

ENGINE SPECIFICATIONS

SPEC

EAS20290

ENGINE SPECIFICATIONS
Item

Standard

Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Engine idling speed
Vacuum pressure at idling speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel

Air-cooled 4-stroke, SOHC
0.113 L (113 cm3)
Forward-inclined single cylinder
50.0 × 57.9 mm (1.97 × 2.28 in.)
9.3 : 1
1500~1700 r/min
48~50 kPa (365~380 mmHg) at 1650 r/min
1300 kPa (13 kgf/cm2, 185 psi) at 1350 r/min

0.9 L

Periodic oil change
Total amount (overhaul)
Oil filter
Oil filter type
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Outer-rotor-to-oil-pump-housing
clearance
Spark plug
Type (manufacturer) × quantity
Spark plug gap
Cylinder head
Max. warpage

-------------------------

Unleaded gasoline or gasohol (91 min. pump
---Regular unleaded gasoline only
octane)
4.4 L (0.97 lmp.gal, 1.16 US gal)
----

Fuel tank capacity
Engine oil
Lubrication system
Recommended engine oil type
Recommended engine oil grade
Engine oil quantity
Periodic oil change
Total amount (overhaul)
Final transmission oil
Recommended oil

Limit

Wet sump
YAMALUBE 4-AT SAE10W-40
API service SG type or higher, JASO standard
MB

----------

0.8 L (0.70 lmp.qt, 0.85 US qt)
1.0 L (0.88 lmp.qt, 1.06 US qt)

-------

YAMALUBE Gear or SAE10W-30 type SE motor
oil, API service
0.10 L (0.088 lmp.qt, 0.11 US qt)
0.11 L (0.097 lmp.qt, 0.12 US qt)

----

Wire mesh

----

Trochoid type
0.15 mm (0.0059 in.) or less

---0.23 mm
(0.0091 in.)
0.19 mm
(0.0074 in.)

0.06~0.11 mm (0.0023~0.0043 in.)

-------

CR6HSA (NGK) × 1
0.6~0.7 mm (0.024~0.028 in.)

-------

----

0.05 mm
(0.002 in)

2-2


52BF8197E0.book Page 3 Wednesday, July 20, 2011 11:01 AM

ENGINE SPECIFICATIONS
Item
Camshaft
Drive system
Intake camshaft lobe dimensions
IN
“A”
“B”

Exhaust camshaft lobe dimensions
EX
“A”
“B”

Max. camshaft runout

Rocker arm/rocker arm shaft
Rocker arm inside diameter
Rocker arm shaft outside diameter
Rocker-arm-to-rocker-arm-shaft
clearance
Timing chain
Model / number of links
Tensioning system

SPEC

Standard

Limit

Chain drive (left)

----

26.169~26.269 mm (1.0302~1.0342 in.)

26.069 mm
(1.0263 in.)
20.975 mm
(0.8257 in.)

21.075~21.175 mm (0.8297~0.8336 in.)

25.841~25.941 mm (1.0174~1.0213 in.)
20.963~21.063 mm (0.8253~0.8292 in.)

25.741 mm
(1.0134 in.)
20.863 mm
(0.8214 in.)

----

0.03 mm
(0.0012 in)

10.000~10.015 mm (0.3937~0.3943 in.)
9.981~9.991 mm (0.3930~0.3933 in.)
0.009~0.034 mm (0.00035~0.00134 in.)

----------

DID SCR-0404 SV / 90
Automatic

-------

2-3


52BF8197E0.book Page 4 Wednesday, July 20, 2011 11:01 AM

ENGINE SPECIFICATIONS
Item

SPEC

Standard

Valve, valve seat, valve guide
Valve clearance (cold)

IN
EX

0.06~0.10 mm (0.0024~0.0039 in.)
0.10~0.14 mm (0.0039~0.0055 in.)

Limit
-------

Valve dimensions

Head Diameter

Face Width

Seat Width

Margin Thickness

“A” head diameter

IN
EX

22.9~23.1 mm (0.9016~0.9094 in.)
19.9~20.1 mm (0.7834~0.7913 in.)

-------

“B” face width

IN
EX

1.202~2.488 mm (0.0473~0.0979 in.)
1.626~2.610 mm (0.0640~0.1028 in.)

-------

“C” seat width

IN
EX

0.9~1.1 mm (0.0354~0.0433 in.)
0.9~1.1 mm (0.0354~0.0433 in.)

1.6 mm (0.0629 in.)
1.6 mm (0.0629 in.)

“D” margin thickness

IN
EX

0.7 mm (0.0275 in.)
1.0 mm (0.0394 in.)

-------

Stem outside diameter

IN
EX

4.970~4.985 mm (0.1956~0.1962 in.)
4.955~4.970 mm (0.1951~0.1957 in.)

4.940 mm (0.1945 in.)
4.925 mm (0.1939 in.)

Guide inside diameter

IN
EX

5.000~5.012 mm (0.1968~0.1973 in.)
5.000~5.012 mm (0.1968~0.1973 in.)

5.050 mm (0.1988 in.)
5.050 mm (0.1988 in.)

Valve stem-to-guide clearance

IN
EX

0.015~0.042 mm (0.0006~0.0016 in.)
0.030~0.057 mm (0.0012~0.0022 in.)

0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)

----

0.01 mm (0.0004 in.)

0.9~1.1 mm (0.0354~0.0433 in.)
0.9~1.1 mm (0.0354~0.0433 in.)

1.6 mm (0.0630 in.)
1.6 mm (0.0630 in.)

33.02 mm (1.30 in)
24.10 mm (0.949 in)

31.36 mm (1.23 in)
-------

-------

Max. valve stem runout

Cylinder head valve seat width

IN
EX

Valve spring
Free length
IN/EX
Installed length (valve closed)
IN/EX
Compression spring force (installed)
IN

Spring tilt*

IN/EX

132.6~152.6 N (13.5~15.6 kgf,
29.8~34.39 lbf)
132.6~152.6 N (13.5~15.6 kgf,
29.8~34.39 lbf)
----

Winding direction (top view)

IN
EX

Clockwise
Clockwise

EX

2-4

---2.5°/1.4 mm
(2.5°/0.055 in.)


52BF8197E0.book Page 5 Wednesday, July 20, 2011 11:01 AM

ENGINE SPECIFICATIONS
Item
Cylinder
Bore

SPEC

Standard

Limit

50.000~50.023 mm
(1.9685~1.9694 in.)
-------

----

0.016~0.030 mm (0.0006~0.0012 in.)
49.977~50.000 mm (1.9675~1.9685 in.)

0.15 mm (0.0059 in.)
----

8.0 mm (0.3150 in.)
13.002~13.013 mm (0.5119~0.5123 in.)
0.5 mm (0.020 in.) / Intake side

---13.043 mm (0.5135 in.)
----

12.996~13.000 mm (0.5116~0.5118 in.)
0.002~0.017 mm (0.00008~0.00067 in.)

12.976 mm (0.5108 in.)
0.067 mm (0.00264 in.)

Ring type
Dimension (B × T)
End gap (installed)
Ring side clearance
2nd ring

Barrel
1.0 × 1.7 mm (0.0394 × 0.0669 in.)
0.1~0.2 mm (0.00394~0.00787 in.)
0.03~0.07 mm (0.00118~0.00276 in.)

-------0.40 mm (0.01575 in.)
0.12 mm (0.00472 in.)

Ring type
Dimension (B × T)
End gap (installed)
Ring side clearance
Oil ring

Taper
1.0 × 1.7 mm (0.0394 × 0.0669 in.)
0.1~0.25 mm (0.00394~0.00984 in.)
0.02~0.06 mm (0.00079~0.00236 in.)

------0.52 mm (0.0205 in.)
0.12 mm (0.0047 in.)

Dimension (B × T)
End gap (installed)
Ring side clearance

2.0 × 2.0 mm (0.0787 × 0.0787 in.)
0.20~0.70 mm (0.00787~0.02756 in.)
0.04~0.16 mm (0.00157~0.00630 in.)

----------

Max. taper
Max. out-of-round
Piston
Piston-to-cylinder clearance
Diameter D

Height H
Piston pin bore diameter (inside)
Offset / Offset direction
Piston pin
Outside diameter
Piston-pin-to-piston-pin-bore clearance
Piston ring
Top ring

2-5

0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)


52BF8197E0.book Page 6 Wednesday, July 20, 2011 11:01 AM

ENGINE SPECIFICATIONS
Item
Connecting rod
Connecting rod length
Small end inside diameter
Crankshaft

Crank width “A”
Max. runout “C”
Big end side clearance “D”
Big end radial clearance “E”
Clutch
Clutch type
Clutch shoe thickness
Clutch shoe spring free length
Clutch housing inside diameter
Compression spring free length
Weight outside diameter
Primary sheave weight / quantity
Clutch - in revolution
Clutch - stall revolution
V-belt
V-belt width
Transmission
Transmission type
Primary reduction ratio
Final drive
Secondary reduction ratio
Variation ratio
Air filter type
Fuel pump
Pump type
Model (manufacturer) × quantity
Maximum consumption amperage
Output pressure
Throttle body
Model (manufacturer) × quantity
Throttle grip free play
ID mark
Engine idling speed
tail pipe)
CO% (rear exhaust (muuffler
pipe)
Oil temperature (°C)

SPEC

Standard

Limit

93.4~93.6 mm (3.677~3.685 in.)
13.015~13.028 mm (0.5124~0.5129 in.)

-------

45.45~45.50 mm (1.789~1.791 in.)
---0.15~0.45 mm (0.0059~0.0177 in.)
0.004~0.014 mm (0.000157~0.000551 in.)

---0.03 mm (0.00118 in.)
1.0 mm (0.0394 in.)
----

Automatic centrifugal (dry type)
2.2 mm (0.0866 in.)
28.5 mm (1.122 in.)
112 mm (4.409 in.)
101.5 mm (3.996 in.)
15 mm (0.591 in.)
9.5 grams / 6 units
2800~3200 r/min
4700~5300 r/min

---1.2 mm (0.0472 in.)
---112.5 mm (4.429 in.)
---14.5 mm (0.571 in.)
----------

18.0 mm (0.7087 in.)

16.2 mm (0.6378 in.)

V-belt automatic
1.00 : 1
Gear
9.400 (47/15 × 39/13)
2.159~0.837:1
Oil-coated paper element

-------------------

Electrical
18S (AISAN) × 1
1.6 A
324 kPa (3.24 kgf/cm2, 46.1 psi)

-------------

x1
SE AC26-11 (MIKUNI) × 1 SE AC26 - 14------1.5~3.5 mm (0.059~0.138 in.)
---52B1 00 1DR1 -00
---1500~1700 r/min
0.0 ~ 4.5 %
---0.0~2.5%
---80°C (176°F)

2-6


52BF8197E0.book Page 7 Wednesday, July 20, 2011 11:01 AM

CHASSIS SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS
Item
Frame
Frame type
26.1
Caster angle
Trail
90 mm
Front wheel
Wheel type
Rim size
Rim material
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Tire bend limit
Rear wheel
Wheel type
Rim size
Rim material
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Front tire
Tire type
Size
Manufacturer / model
Tire pressure (cold)
One rider
Two riders
Min. tire tread depth
Rear tire
Tire type
Size
Manufacturer / model
Tire pressure (cold)
One rider
Two riders
Min. tire tread depth
Front brake
Brake type
Operation
Brake lever free play (at lever end)
Brake discs
Disc outside diameter × thickness
Brake disc thickness limit
Brake disc deflection limit
Brake pad lining thickness (inner)
Brake pad lining thickness (outer)
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid

Standard

Limit

Steel tube back bone
26.5°
91 mm (3.583 in.)

----------

Cast wheel
12 × 2.15
Aluminum
74 mm (2.913 in.)
----------

------------1.0 mm (0.04 in.)
1.0 mm (0.04 in.)
0.25 mm (0.01 in.)

Cast wheel
12 × 2.15
Aluminum
70 mm (2.756 in.)
-------

------------1.0 mm (0.04 in.)
1.0 mm (0.04 in.)

Tubeless
90/90 12 54J 90/90 12 44J
IRC / MB82 MAXXIS/ M6219

----------

175 kPa (1.75 kgf/cm2, 25 psi)
175 kPa (1.75 kgf/cm2, 25 psi)
----

------1.0 mm (0.04 in.)

Tubeless
90/90 12 54J
IRC / MB81 MAXXIS/ M6220

----------

200 kPa (2.00 kgf/cm2, 29 psi)
200 kPa (2.00 kgf/cm2, 29 psi)
----

------1.0 mm (0.04 in.)

Single disc brake
Right hand operation
11.00~17.00 mm (0.43~0.67 in.)

----------

180 × 4 mm (7.087 × 0.157 in.)
------5.3 mm (0.21 in.)
5.3 mm (0.21 in.)
11 mm (0.43 in.)
33.34 mm (1.31 in.)
DOT 3 or DOT 4

---3.5 mm (0.138 in.)
0.15 mm (0.006 in.)
0.8 mm (0.031 in.)
0.8 mm (0.031 in.)
----------

2-7


52BF8197E0.book Page 8 Wednesday, July 20, 2011 11:01 AM

CHASSIS SPECIFICATIONS
Item
Rear brake
Brake type
Operation
Brake lever free play (at lever end)
Brake drum inner diameter
Brake shoe thickness
Shoe spring free length (camshaft side)
Shoe spring free length (pivot side)
Steering
Steering bearing type
Center to lock angle (left)
Center to lock angle (right)
Front suspension
Suspension type
Spring / shock absorber type
Front fork travel
Fork spring
Free length
Installed length
Spring rate (K1)
Spring rate (K2)
Spring stroke (K1)
Spring stroke (K2)
Optional spring available
Front fork oil
Recommended oil type
Quantity (each front fork leg)
Oil level
Inner tube outer diameter
Inner tube bending limit
Rear suspension
Suspension type
Spring / shock absorber type
Rear shock absorber assembly travel
Spring
Free length
Installed length
Spring rate (K1)
Spring rate (K2)
Spring stroke (K1)
Spring stroke (K2)
Optional spring available

SPEC

Standard

Limit

Drum brake
Left hand operation
10~20 mm (0.39~0.78 in.)
130 mm (5.12 in.)
4.0 mm (0.16 in.)
52 mm (2.05 in.)
48 mm (1.89 in.)

---------131 mm (5.16 in.)
2.0 mm (0.079 in.)
-------

Angular bearing
48°
48°

----------

Telescopic fork
Coil spring / oil damper
85 mm (3.35 in.)

----------

261.7 mm (10.30 in.)
249.7 mm (9.83 in.)
3.8 N/mm (0.39 kgf/mm, 21.69 lb/in.)
7.55 N/mm (0.77 kgf/mm, 43.10 lb/in.)
0~60.0 mm (0~2.36 in.)
60.0~85.0 mm (2.36~3.35 in.)
No

256.5 mm (10.10 in.)
-------------------

YAMAHA Suspension oil G10 or
equivalent fork oil
55.0 c.c.
78 mm (3.07 in.)
26 mm (1.02 in.)
----

----

Unit swing arm
Coil spring / oil damper
72 mm (2.83 in.)

----------

249.6 mm (9.83 in.)
245.6 mm (9.67 in.)
31.5 N/mm (3.21 kgf/mm, 179 lb/in.)
42 N/mm (4.28 kgf/mm, 239.67 lb/in.)
0~35.5 mm (0~1.40 in.)
35.5~72.0 mm (1.40~2.83 in.)
No

----------------------

2-8

---------0.2 mm (0.008 in.)


52BF8197E0.book Page 9 Wednesday, July 20, 2011 11:01 AM

ELECTRICAL SPECIFICATIONS

SPEC

ELECTRICAL SPECIFICATIONS
Item
System voltage
Ignition system
Ignition system type
Ignition timing
Advance type
Crankshaft position sensor resistance /
color
Transistor ignition unit style /
manufacturer
Ignition coil
Model / manufacturer
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Spark plug cap
Material
Resistance
Charging system
System type
Model (manufacturer)
Standard output
Charging current (min.)
Charging current (max.)
Charging coil resistance / color
Rectifier/regulator
Model (manufacturer)
No load regulated voltage
Rectifier capacity
Withstand voltage
Battery
Battery type (manufacturer)
Battery voltage / capacity
Specific gravity
Headlight bulb type
Indicator and warning light
(voltage / wattage × quantity)
Turn signal indicator light
High beam indicator
Engine trouble warning light
Bulbs (voltage / wattage × quantity)
Headlight
Tail/brake light
Front turn signal light
Rear turn signal light
Meter light
Fuses (amperage × quantity)
Main fuse

Standard

Limit

12 V

----

Transistorized Coil Ignition (T.C.I.)
10° BTDC at 1600 r/min
Digital
248~372 Ω at 20°C (68°F) / (W/R-W/L)

-------------

52B0 / MORIC (YEJP)

----

52B0 / YAMAHA MOTOR
ELECTRONICS (Thailand)
6 mm (0.24 in.)
2.16~2.64 Ω at 20°C (68°F)
8.64~12.96 kΩ at 20°C (68°F)

----

Synthetic resin
7.5~12.5 kΩ at 20°C (68°F)

-------

AC magneto
52B0 / YAMAHA MOTOR
ELECTRONICS (Thailand)
14 V 160 W at 5000 r/min
7.9 A or higher at 1500 r/min
13 A or lower at 5000 r/min
0.496~0.744 Ω at 20°C (68°F) / (W-W)

-------

18S (CHONGQING HECHENG)
14.1~14.9 V
25 A
200 V

-------------

YTZ6V (YUASA) YTX5L-BS
12 V / 5 AH
12V, 4A
1.340
Incandescence

-------------

14 V 3 W × 1
14 V 3 W × 1
14 V 3 W × 1

----------

12 V 32 W/32 W × 1 12V, 35W/ 35W x 1
12 V 5 W/21 W × 1
12 V 10 W × 2
12 V 10 W × 2
12 V 1.7 W × 2

----------------

15 A × 1

----

2-9

----------

-------------


52BF8197E0.book Page 10 Wednesday, July 20, 2011 11:01 AM

ELECTRICAL SPECIFICATIONS
Item
Electric starting system
System type
Starter motor
Model (manufacturer)
Operating voltage
Power output
Brush
Overall length
Quantity
Spring force
Armature coil resistance
Commutator diameter
Mica undercut
Starter relay
Model (manufacturer)
Amperage
Coil resistance
Operating voltage
Horn
Horn type
Model (manufacturer)
Maximum amperage
Performance
Coil resistance
Turn signal relay
Relay type
Model (manufacturer)
Built-in, self-canceling device
Turn signal blinking frequency
Wattage
Fuel gauge
Model (manufacturer)
Sender unit resistance
Full
Empty
ISC (idling speed control valve)
Coil resistance / color
Intake temperature sensor
Coil resistance / color
Intake pressure sensor
Output voltage / color
Throttle position sensor
Voltage / color
Output voltage (with throttle valve
closed) / color
Engine temperature sensor
Model (manufacturer)
Coil resistance
Lean angle sensor
Voltage
Lower than 65°
Higher than 65°
O2 sensor
Model (manufacturer)
Coil resistance

SPEC

Standard

Limit

Constant mesh

----

52B (YETH)
12 V
0.28 kW

----------

7 mm (0.28 in.)
2
3.92~5.88 N/mm (0.4~0.6 kgf/mm,
35.27~33.60 lb/in.)
0.0279~0.0341 Ω at 20°C (68°F)
17.6 mm (0.69 in.)
1.35 mm (0.05 in.)

3.5 mm (0.14 in.)
-------

G4R-F18 (OMRON)
50 A
54.00~66.00 Ω at 20°C (68°F)
DC 8 V at 20°C

-------------

Plane
10B1 (NIKKO)
1.0 A
95~115 dB/2 m
4.024~4.176 Ω at 20°C (68°F)

----------------

Full transistor
FB218BH (DENSO)
No
75~95 cycles/min
10 W × 2 + 3.4 W

----------------

18S (AISAN)

----

4~10 Ω at 20°C (68°F)
90~100 Ω at 20°C (68°F)

-------

20 Ω / (P-G/Y or Gy-Sb)

----

5.7~6.3 kΩ at 0°C / (Br/W-B/L)

----

0.789~4 V at 20.0~101.3 kPa / (P/W-B/L)

----

5 V / (L-B/L)
0.68 V / (Y-B/L)

-------

52B1 (PANASONIC)
2.512~2.777 kΩ at 20°C (68°F)
210.2~220.9 Ω at 100°C (212°F)

----------

0.4~1.4 V
3.7~4.4 V

-------

52B1 (DENSO)
Below 5 kΩ at 370°C (698°F) (exhaust
gas temperature)

-------

2-10

---16.6 mm (0.65 in.)
----


52BF8197E0.book Page 11 Wednesday, July 20, 2011 11:01 AM

CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS

SPEC

EAS00028

EAS00030

CONVERSION TABLE

GENERAL TIGHTENING TORQUE
SPECIFICATIONS

All specification data in this manual are listed in SI
and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
Ex.
METRIC
** mm
2 mm

×
×

MULTIPLIER
0.03937
=
0.03937
=

This chart specifies tightening torques for standard
fasteners with a standard ISO thread pitch.
Tightening torque specifications for special
components or assemblies are provided for each
chapter of this manual. To avoid warpage, tighten
multi-fastener assemblies in a crisscross pattern
and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications require
clean, dry threads. Components should be at room
temperature.

IMPERIAL
** in
0.08 in

CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit

Multiplier

Imperial unit

Tightening torque

m·kg
m·kg
cm·kg
cm·kg

7.233
86.794
0.0723
0.8679

ft·lb
in·lb
ft·lb
in·lb

Weight

kg
g

2.205
0.03527

lb
oz

Speed

km/hr

0.6214

mph

Distance

km
m
m
cm
mm

0.6214
3.281
1.094
0.3937
0.03937

mi
ft
yd
in
in

3

Volume/
Capacity

cc (cm )
cc (cm3)
lt (liter)
lt (liter)

0.03527
0.06102
0.8799
0.2199

oz (lMP liq.)
cu.in
qt (IMP liq.)
gal (lMP liq.)

Misc.

kg/mm
kgf/cm2
Centigrade
(°C)

55.997
14.2234
9/5+32

lb/in
psi (lb/in2)
Fahrenheit
(°F)

A: Distance between flats
B: Outside thread diameter

2-11

A
nut
(mm)

B
bolt
(mm)

10

General tightening torques
Nm

m·kg

ft·lb

6

6

0.6

4.3

12

8

15

1.5

11

14

10

30

3.0

22

17

12

55

5.5

40

19

14

85

8.5

61

22

16

130

13.0

94


52BF8197E0.book Page 12 Wednesday, July 20, 2011 11:01 AM

TIGHTENING TORQUES

SPEC

TIGHTENING TORQUES
ENGINE
Part to be tightened

Part
name

Thread
size

Q’ty




Nut

M8
M6
M45
M8


Bolt
Nut
Bolt
Bolt
Bolt

Tightening torque
Nm

m·kg

ft·lb

2
1
2
4

20
10
17.5
22

2.0
1.0
1.75
2.2

14.46
1.23
12.66
15.91

M10
M6
M5
M8
M6
M6

1
2
2
1
2
1

12.5
10
7
30
8.5
12

1.25
1.0
0.7
3.0
0.85
1.2

9.04
7.23
5.06
21.70
6.15
8.68

Bolt
Bolt
Bolt
Screw
Tapping
Screw
Bolt
Screw

M6
M6
M6
M6
M6

1
2
2
2
2

10
10
7
6.5
2

1.0
1.0
0.1
0.65
0.2

7.23
7.23
5.06
4.70
1.45

M6
M6

4
1

8.5
6.5

0.85
0.65

6.15
4.70

Screw

M6

1

2

0.2

1.45

Bolt

M6

1

2

0.2

1.45

Screw

Bolt
Bolt
Bolt


M5
M30
M6
M6
M6
M4

2
1
2
1
2
1

4
20
10
10
10
3.5

0.4
2.0
1.0
1.0
1.0
0.35

2.9
14.46
7.23
7.23
7.23
2.53

Side circlip, air filter



M4

1

2.5

0.25

1.81

Exhaust pipe guard

Screw

M6

2

8.5

0.85

6.15

Bolt
Bolt
Bolt
Bolt


M8
M6
M6
M6
M8

2
9
3
7
4

31
10
10
10
12.5

3.1
1.0
1.0
1.0
1.25

22.42
7.23
7.23
7.23
9.04



M6

1

13

1.3

9.40

Front exhaust pipe nut
Check bolt
Valve cover
Cylinder head and cylinder assembly
nut
Spark plugs
Cylinder head (chain side)
Valve adjusting locknut
Camshaft sprocket
Timing chain tensioner
Camshaft retainer
Timing chain guide
Timing chain guide plate
Cam sprocket cover
Engine cooling fan cover
Engine cooling fan cover
Fan
Engine cooling fan cover (ignition coil
guide)
Engine cooling fan cover (ignition coil
guide)
Breather hose bracket
Oil pump assembly
Oil drain plug
Intake manifold
Fuel injector
Air filter
Side circlip, intake manifold

Exhaust pipe
Left crankcase and right crankcase
Right crankcase cover
Left crankcase cover
Stud bolt, cylinder head (left/right
crankcase)
Transmission oil drain bolt

2-12

Remarks

M

Until it goes
against the
collar
Until it goes
against the
collar

Height
management


52BF8197E0.book Page 13 Wednesday, July 20, 2011 11:01 AM

TIGHTENING TORQUES

SPEC

Tightening torque

Part
name

Thread
size

Q’ty

Transmission oil filler bolt

Bolt

M8

1

Transmission case cover
V-belt case
Engine oil filler cap

Bolt
Bolt


M6
M6
M20

7
8
1


Bolt
Screw
Nut
Nut
Bolt
Screw
Nut
Bolt
Screw


M12
M5
M4
M12
M10
M6
M6
M12
M6
M6
M10

1
6
2
1
1
3
2
1
2
2
1

20
7
1.8
50
40
10
6.5
70
10
6.5
18

2.0
0.7
0.18
5.0
4.0
1.0
0.65
7.0
1.0
0.65
1.8

14.46
5.06
1.30
36.16
28.93
7.23
4.70
50.63
7.23
4.70
13.02



M18

1

45

4.5

32.55

Part to be tightened

Engine oil drain bolt
V-belt case air filter cover
V-belt case air filter cover plate clamp
Primary fixed sheave
Clutch housing
Stator coil
Crankshaft position sensor
AC magneto rotor
Start motor assembly
Ignition coil
Engine temperature sensor

O2 sensor

Nm

m·kg

ft·lb

20

2.0

14.46

10
1.0
7.23
10
1.0
7.23
Seat and surface
must be tightly fitted.

Cylinder head tightening sequence:

3
1
5

6
4

2

2-13

Remarks
Transmission
oil inlet

Pay special
attention
when
tightening
the bolt

Do not use
pneumatic
tool to
tighten
Do not use
pneumatic
tool to
tighten


52BF8197E0.book Page 14 Wednesday, July 20, 2011 11:01 AM

TIGHTENING TORQUES

SPEC

CHASSIS
Tightening torque

Thread
size

Nm

m·kg

ft·lb

Engine bracket and frame complete
Engine bracket and engine assembly
Engine bracket and engine assembly
Rear shock absorber and frame
Rear shock absorber and engine
Bracket and handlebar complete
Lower bracket pinch bolt
Steering ring nut
Damper rod assembly bolt
Throttle cable holder and right lever screw
Speedometer cable
Fuel pump
Fuel hose clamp
Fuel tank and frame bolt
Fuel sub-tank and bracket
Fuel tank cover bolt

M10
M10
M8
M10
M8
M10
M10
M25
M8
M5

M5
M6
M6
M6
M6

50
50
30
28
21
50
53

23
4
3
4
6.5
14
10
14

5.0
5.0
3.0
2.8
2.1
5.0
5.3

2.3
0.4
0.3
0.4
0.65
1.4
1.0
1.4

36.17
36.17
21.70
20.25
15.19
36.17
38.33

16.64
2.90
2.20
2.90
4.70
10.13
7.23
10.13

Fuel tank cap bolt

M4

2

0.2

1.45

Brake lever and frame bolt
Footboard and frame bolt
Center cover and footboard screw
Front wheel axle nut
Rear wheel axle nut
Rear brake cam arm bolt
Main switch and frame bolt
Keyhole cover bolt
Hook and frame screw
Centerstand pivot
Sidestand pivot
Rear brake cable holder and left crankcase bolt
Headlight lens and meter cover
Brake caliper bleed screw
Brake hose union bolt
Brake caliper bolt
Brake hose and lower bracket
Brake hose and front fork
Brake hose guide
Rear view mirror
Air filter and rear fender
O2 sensor and rear fender
Rectifier regulator and frame
Horn bracket
Upper master cylinder screw
Front fender
Grab bar
Seat
Storage compartment and frame
Front brake disc bolt

M6
M6
M5
M10
M14
M6
M6
M5
M6
M8
M8
M6
M5
M7
M10
M10
M6
M6
M6
M10
M6
M6
M6
M6
M4
M6
M8
M6
M6
M8

7
7
4
40
140
10
7
4
7
23
24
7
2
6
26
35
7
7
7
32
6
7
7
7
2
7
23
7
10
23

0.7
0.7
0.4
4.0
14
1.0
0.7
0.4
0.7
2.3
2.4
0.7
0.2
0.6
2.6
3.5
0.7
0.7
0.7
3.2
0.6
0.7
0.7
0.7
0.2
0.7
2.3
0.7
1.0
2.3

5.06
5.06
2.90
28.93
101.26
7.23
5.06
2.90
5.06
16.63
17.36
5.06
1.45
4.34
18.80
25.32
5.06
5.06
5.06
23.15
4.34
5.06
5.06
5.06
1.45
5.06
16.64
5.06
7.23
16.64

Part to be tightened

2-14

Remarks

See “TIP”


52BF8197E0.book Page 15 Wednesday, July 20, 2011 11:01 AM

TIGHTENING TORQUES

SPEC

TIP
• Tighten the lower steering ring nut 38 Nm (3.8 m·kg, 27 ft·lb) with a torque wrench and the steering nut
wrench, and then loosen the nut 1/4 turn.
• Tighten the lower steering ring nut 12 Nm (1.2 m·kg, 8.7 ft·lb) with atorque wrench and the steering nut
wrench.
• Install the washer and the center steering ring nut.
• Finger tighten the center steering ring nut, align the slots of both steering ring nuts, and then install the lock
wssher.
• Hold the lower and center steering ring nuts, and then tighten the upper steering ring nut 75 Nm
(7.5 m·kg, 54 ft·lb) with a torgue wrench and the steering nut wrench.

4 5
3
2
1

1. Lower ring nut
1 Lower ring nut 2. Rubber washer
2 Upper ring nut 3. Center ring nut
4. Lock washer
5. Upper ring nut

2-15


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