Manufacturer: YAMAHA, Model Year: 2003,
Model line: WR 450F,
Model: YAMAHA WR 450F 2003
Pages: 754, PDF Size: 41.41 MB
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Yamaha WR450F
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Для Yamaha WR450
- Сервисный мануал (Owners Service Manual) на Yamaha WR450FA (2011)
- Руководство пользователя (Owners Manual) на Yamaha WR450F (2012)
- Сервисный мануал (Owners Service Manual) на Yamaha WR450FR (2002)
- Сервисный мануал (Owners Service Manual) на Yamaha WR450FS (2003)
- Сервисный мануал (Owners Service Manual) на Yamaha WR450FT (2004)
- Сервисный мануал (Owners Service Manual) на Yamaha WR450FW (2006)
Обзор модели
- Yamaha WR450
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Complete 2003-2005 Yamaha Wr450f service repair manual. It’s your number one source for repair and service information. They are specifically written for the do-it-yourselfer as well as the experienced mechanic.Dwonload Service Repair Manual for Yamaha Wr450f 2003 2004 2005 This highly detailed digital repair manual contains everything you will ever need to repair, maintain, rebuild, refurbish or restore your 2003 2004 2005 Yamaha Wr450f. www.RapidshareJet.com Page 1/46 Topics overed:
Yamaha Wr450f 2003-2005 Service Repair Manual
Download Now
Complete 2003-2005 Yamaha Wr450f service repair manual. It’s your number one source
for repair and service information. They are specifically written for the do-it-yourselfer as
well as the experienced mechanic.Dwonload Service Repair Manual for Yamaha Wr450f
2003 2004 2005
This highly detailed digital repair manual contains everything you will ever need to
repair, maintain, rebuild, refurbish or restore your 2003 2004 2005 Yamaha Wr450f.
This is the same information the dealer technicians and mechanics use to diagnose and
repair your bike. With this professional quality highly detailed service repair manual, you
will be able to work on your bike with the best resources available, which will not only
save you a lot of money in repair bills but will also help you to look after your vehicle.
Topics overed:
www.RapidshareJet.com Page 1/46
. Complete Engine Service
. Fuel System Service
. Factory Repair Procedures
. Wiring Diagrams
. Gearbox
. Exhaust System
. Suspension
. Fault Finding
. Clutch Removal and Installation
. Front Suspension
. Bodywork
. Gearbox Service, Removal and Installation
. Cooling System
. Detailed Specifications
. Transmission
. Factory Maintenance Schedules
. Electrics
. Engine Firing Order
. Brake Servicing Procedures
. Driveshaft
. Timing Chain Service
. Exhaust Service
. Abundant Illustrations
. Lots of Pictures & Diagrams
. Plus Lots More
Related tags: Change oil, Yamaha Wr450f, Service Manual, Cooling System, Engine,
Diagnose, Starter, 4-Cylinder, 6-Cylinder, Spark plugs, Brakes, Air Conditioner, Battery,
Suspension, Shop Manual, Steering, Air Bags, Coolant, Air Filter, Troubleshooting,
Alternator, Radiator, Timing Belt, Repair Manual
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OWNER’S SERVICE MANUAL
WR450FR
LIT-11626-16-43 |
5TJ-28199-10 |
EC010000
WR450FR
OWNER’S SERVICE MANUAL
©2002 by Yamaha Motor Corporation, U.S.A. 1st Edition, October 2002
All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited.
Printed in Japan
P/N. LIT-11626-16-43
EC020000
INTRODUCTION
Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.
NOTE:
As improvements are made on this model, some data in this manual may become outdated. If you have any questions, please consult your Yamaha dealer.
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
IMPORTANT NOTICE
THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding.
SAFETY INFORMATION
1.THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics.
2.THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine.
3.ALWAYS WEAR PROTECTIVE APPAREL.
When operating this machine, always wear an approved helmet with goggles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine.
4.ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER.
For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident.
5.GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking.
6.GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.
7.ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
8.PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE.
Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over.
9.THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
10.PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.
When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.
EC050000
TO THE NEW OWNER
This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer.
NOTE:
This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.
EC060000
NOTICE
Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer.
EC070001
F.I.M. MACHINE WEIGHTS:
Weights of machines without fuel
The minimum weights for motocross machines are:
for the class 125 cc |
………………….. minimum |
88 kg (194 lb) |
|
for the class 250 cc ………………….. |
minimum |
98 kg (216 lb) |
|
for the class 500 cc ………………….. |
minimum |
102 kg (225 lb) |
In modifying your machine (e.g., for weight reduction), take note of the above limits of weight.
EC080000
HOW TO USE
THIS MANUAL
EC081000
PARTICULARLY IMPORTANT INFORMATION
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the machine.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
EC082000
FINDING THE REQUIRED PAGE
1.This manual consists of seven chapters; “General Information”, “Specifications”, “Regular inspection and adjustments”, “Engine”, “Chassis”, “Electrical” and “Tuning”.
2.The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item.
Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.
EC083000
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.,
●Bearings
Pitting/damage → Replace.
EC084002
HOW TO READ DESCRIPTIONS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
1.An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.
2.Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.
3.An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 3. The meanings of the symbol marks are given on the next page.
4.A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
5.Extent of removal 5 is provided in the job instruction chart to save the trouble of an unnecessary removal job.
6.For jobs requiring more information, the step-by-step format supplements 6 are given in addition to the exploded diagram and job instruction chart.
1 |
2 |
|
GEN |
SPEC |
|
INFO |
||
3 |
4 |
|
INSP |
ENG |
|
ADJ |
||
5 |
6 |
|
CHAS |
ELEC – |
+ |
7 |
8 |
|
T U N |
||
9 |
0 |
|
A |
B |
|
T |
||
. |
||
R |
||
. |
||
C |
D |
|
E |
F |
|
E |
M |
|
G |
H |
|
B |
M |
|
I |
J |
|
New |
ILLUSTRATED SYMBOLS (Refer to the illustration)
Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content.
1 General information
2 Specifications
3 Regular inspection and adjustments
4 Engine
5 Chassis
6 Electrical
7 Tuning
Illustrated symbols 8 to D are used to identify the specifications appearing in the text.
8 With engine mounted
9 Special tool
0 Filling fluid A Lubricant B Tightening
C Specified value, Service limit
D Resistance (Ω), Voltage (V), Electric current (A)
Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and location of lubrication point.
E Apply engine oil
F Apply molybdenum disulfide oil
G Apply lightweight lithium-soap base grease H Apply molybdenum disulfide grease
Illustrated symbols I to J in the exploded diagrams indicate where to apply a locking agent and where to install new parts.
I Apply locking agent (LOCTITE®)
J Use new one
MEMO
GENERAL INFORMATION
GEN 1 INFO
SPECIFICATIONS
SPEC 2
REGULAR |
||||||
INSPECTION AND |
||||||
INSP |
3 |
|||||
ADJUSTMENTS |
||||||
ADJ |
||||||
ENGINE
ENG 4
CHASSIS
CHAS 5
– +
ELECTRICAL
ELEC 6
TUNING
TUN 7
EC0A0000
CONTENTS
CHAPTER 1
GENERAL INFORMATION
DESCRIPTION …………………………………… |
1-1 |
MACHINE IDENTIFICATION ……………….. |
1-2 |
IMPORTANT INFORMATION ………………. |
1-3 |
CHECKING OF CONNECTION …………….. |
1-6 |
SPECIAL TOOLS ……………………………….. |
1-7 |
CONTROL FUNCTIONS ……………………. |
1-10 |
FUEL ………………………………………………. |
1-14 |
STARTING AND BREAK-IN ………………. |
1-15 |
TORQUE-CHECK POINTS ………………… |
1-19 |
CLEANING AND STORAGE ………………. |
1-20 |
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ……………… |
2-1 |
MAINTENANCE SPECIFICATIONS ……… |
2-4 |
GENERAL TORQUE |
|
SPECIFICATIONS …………………………….. |
2-20 |
DEFINITION OF UNITS ……………………… |
2-20 |
LUBRICATION DIAGRAMS ……………….. |
2-21 |
CABLE ROUTING DIAGRAM …………….. |
2-23 |
CHAPTER 3
REGULAR INSPECTION AND
ADJUSTMENTS
MAINTENANCE INTERVALS ………………. |
3-1 |
PRE-OPERATION INSPECTION |
|
AND MAINTENANCE ………………………….. |
3-4 |
ENGINE …………………………………………….. |
3-5 |
CHASSIS …………………………………………. |
3-26 |
ELECTRICAL …………………………………… |
3-48 |
CHAPTER 4
ENGINE
SEAT, FUEL TANK |
|
AND SIDE COVERS …………………………… |
4-1 |
EXHAUST PIPE AND SILENCER ………… |
4-3 |
RADIATOR ………………………………………… |
4-5 |
CARBURETOR ………………………………….. |
4-8 |
CAMSHAFTS …………………………………… |
4-21 |
CYLINDER HEAD …………………………….. |
4-29 |
VALVES AND VALVE SPRINGS ……….. |
4-33 |
CYLINDER AND PISTON ………………….. |
4-42 |
CLUTCH ………………………………………….. |
4-48 |
OIL FILTER, WATER PUMP |
|
AND CRANKCASE COVER (RIGHT) ….. |
4-55 |
BALANCER ……………………………………… |
4-62 |
OIL PUMP ……………………………………….. |
4-65 |
KICK AXLE AND SHIFT SHAFT ………… |
4-69 |
AC MAGNETO |
|
AND STARTER CLUTCH ………………….. |
4-76 |
ENGINE REMOVAL ………………………….. |
4-83 |
CRANKCASE AND CRANKSHAFT ……. |
4-89 |
TRANSMISSION, SHIFT CAM |
|
AND SHIFT FORK ……………………………. |
4-98 |
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL |
……. 5-1 |
FRONT BRAKE AND REAR BRAKE ….. |
5-11 |
FRONT FORK ………………………………….. |
5-27 |
HANDLEBAR …………………………………… |
5-40 |
STEERING ………………………………………. |
5-46 |
SWINGARM …………………………………….. |
5-52 |
REAR SHOCK ABSORBER ………………. |
5-60 |
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS |
|
AND WIRING DIAGRAM ……………………… |
6-1 |
MAP-CONTROLLED CDI UNIT ……………. |
6-2 |
IGNITION SYSTEM …………………………….. |
6-3 |
ELECTRIC STARTING SYSTEM ………….. |
6-7 |
CHARGING SYSTEM ……………………….. |
6-17 |
TPS (THROTTLE POSITION SENSOR) |
|
SYSTEM ………………………………………….. |
6-19 |
LIGHTING SYSTEM ………………………….. |
6-24 |
CHAPTER 7 |
|
TUNING |
|
ENGINE …………………………………………….. |
7-1 |
CHASSIS …………………………………………. |
7-10 |
GEN
DESCRIPTION INFO
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1 Clutch lever
2 Hot starter lever
3 “ENGINE STOP” button
4 Trip meter
5 Main switch
6 Lights switch
7 Start switch
8 Front brake lever
9 Throttle grip
0 Radiator cap A Fuel tank cap B Taillight
C Kickstarter D Fuel tank E Headlight F Radiator
G Coolant drain bolt H Rear brake pedal I Valve joint
J Fuel cock
K Cold starter knob L Air cleaner
M Drive chain N Shift pedal O Oil dipstick P Front fork
NOTE:
●The machine you have purchased may differ slightly from those shown in the following.
●Designs and specifications are subject to change without notice.
9
A 0
IJKL B C D E F
MACHINE IDENTIFICATION
EC120001
GEN
INFO
MACHINE IDENTIFICATION
There are two significant reasons for knowing the serial number of your machine:
1.When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own.
2.If your machine is stolen, the authorities will need the number to search for and identify your machine.
EC121001
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped on the right of the steering head pipe.
1
EC123001
ENGINE SERIAL NUMBER
The engine serial number 1 is stamped into 1 the elevated part of the right-side of the
engine.
EC124000
MODEL LABEL
The model label 1 is affixed to the frame under the rider’s seat. This information will be needed to order spare parts.
1 — 2
GEN
IMPORTANT INFORMATION INFO
EC130000
IMPORTANT INFORMATION
EC131010
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1.Remove all dirt, mud, dust, and foreign material before removal and disassembly.
When washing the machine with high pressured water, cover the parts as follows.
●Silencer exhaust port
●Side cover air intake port
●Water pump housing hole at the bottom
●Drain hole on the cylinder head (right side)
●All electrical components
2.Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” section.
3.When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced.
4.During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.
5.Keep away from fire.
1 — 3
IMPORTANT INFORMATION
EC132000
GEN
INFO
ALL REPLACEMENT PARTS
1.We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1.All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.
2.Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER PINS
1.All lock washers/plates 1 and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.
EC135001
BEARINGS AND OIL SEALS
1.Install the bearing(s) 1 and oil seal(s) 2 with their manufacturer’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.
1 — 4
GEN
IMPORTANT INFORMATION INFO
EC136000
CIRCLIPS
1.All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite to the thrust
3 it receives. See the sectional view.
4 Shaft
1 — 5
GEN
CHECKING OF CONNECTION INFO
EC1C0001
CHECKING OF CONNECTION
Dealing with stains, rust, moisture, etc. on the connector.
1.Disconnect:
●Connector
2.Dry each terminal with an air blower.
3.Connect and disconnect the connector two or three times.
4.Pull the lead to check that it will not come off.
5.If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector.
6.Connect:
●Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.
NOTE:
●If there in no continuity, clean the terminals.
●Be sure to perform the steps 1 to 7 listed above when checking the wireharness.
●For a field remedy, use a contact revitalizer available on the market.
●Use the tester on the connector as shown.
1 — 6
SPECIAL TOOLS
EC140001
SPECIAL TOOLS
GEN
INFO
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.
NOTE:
●For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.
●For others, use part number starting with “90890-”.
Part number |
Tool name/How to use |
Illustration |
||
YU-1135-A, 90890-01135 |
Crankcase separating tool |
YU-1135-A |
90890-01135 |
|
These tool is used to remove the crankshaft from |
||||
either case. |
||||
YU-3097, 90890-01252 |
Dial gauge and stand |
YU-3097 |
90890-01252 |
|
YU-1256 |
Stand |
YU-1256 |
||
These tools are used to check each part for runout or |
||||
bend. |
||||
Crankshaft installing tool |
YU-90050 |
90890-01274 |
||
YU-90050, 90890-01274 |
Crankshaft installing pot |
YU-90063 |
90890-01275 |
|
YM-91044 |
90890-01278 |
|||
YU-90050, 90890-01275 |
Crankshaft installing bolt |
|||
90890-04081 |
||||
YM-91044, 90890-04081 |
Spacer (crankshaft installer) |
|||
YU-90063, 90890-01278 |
Adapter (M12) |
|||
These tools are used to install the crankshaft. |
||||
YU-1304, 90890-01304 |
Piston pin puller |
YU-1304 |
90890-01304 |
|
This tool is used to remove the piston pin. |
||||
YU-24460-01, 90890-01325 |
Radiator cap tester |
YU-24460-01 |
90890-01325 |
|
YU-33984, 90890-01352 |
Adapter |
YU-33984 |
90890-01352 |
|
These tools are used for checking the cooling sys- |
||||
tem. |
||||
YU-33975, 90890-01403 |
Ring nut wrench |
YU-33975 |
90890-01403 |
|
This tool is used when tighten the steering ring nut to |
||||
specification. |
||||
YM-1423, 90890-01423 |
Damper rod holder |
YM-1423 |
90890-01423 |
|
Use this tool to remove and install the damper rod. |
||||
1 — 7
SPECIAL TOOLS |
GEN |
||||||
INFO |
|||||||
Part number |
Tool name/How to use |
Illustration |
|||||
YM-01442, 90890-01442 |
Fork seal driver |
YM-01442 |
90890-01442 |
||||
This tool is used when install the fork oil seal. |
|||||||
YU-3112-C, 90890-03112 |
Yamaha pocket tester |
YU-3112-C |
90890-03112 |
||||
Use this tool to inspect the coil resistance, output |
|||||||
voltage and amperage. |
|||||||
YU-8036-B |
Inductive tachometer |
YU-8036-B |
90890-03113 |
||||
90890-03113 |
Engine tachometer |
||||||
This tool is needed for observing engine rpm. |
|||||||
YM-33277-A, 90890-03141 |
Timing light |
YM-33277-A |
90890-03141 |
||||
This tool is necessary for checking ignition timing. |
|||||||
YM-4019, 90890-04019 |
Valve spring compressor |
YM-4019 |
90890-04019 |
||||
This tool is needed to remove and install the valve |
|||||||
assemblies. |
|||||||
YM-91042, 90890-04086 |
Clutch holding tool |
YM-91042 |
90890-04086 |
||||
This tool is used to hold the clutch when removing or |
|||||||
installing the clutch boss securing nut. |
|||||||
YM-4116, 90890-04116 |
Valve guide remover |
YM-4116 |
90890-04116 |
||||
YM-4097, 90890-04097 |
Intake 4.5 mm (0.18 in) |
YM-4097 |
90890-04097 |
||||
Exhaust 5.0 mm (0.20 in) |
|||||||
This tool is needed to remove and install the valve |
|||||||
guide. |
|||||||
YM-4117, 90890-04117 |
Valve guide installer |
YM-4117 |
90890-04117 |
||||
YM-4098, 90890-04098 |
Intake |
YM-4098 |
90890-04098 |
||||
Exhaust |
|||||||
This tool is needed to install the valve guide. |
|||||||
YM-4118, 90890-04118 |
Valve guide reamer |
YM-4118 |
90890-04118 |
||||
YM-4099, 90890-04099 |
Intake 4.5 mm (0.18 in) |
YM-4099 |
90890-04099 |
||||
Exhaust 5.0 mm (0.20 in) |
|||||||
This tool is needed to rebore the new valve guide. |
|||||||
1 — 8
SPECIAL TOOLS |
GEN |
||||||
INFO |
|||||||
Part number |
Tool name/How to use |
Illustration |
|||||
YM-04141, 90890-04141 |
Rotor puller |
YM-04141 |
90890-04141 |
||||
This tool is used to remove the flywheel magneto. |
|||||||
YM-34487 |
Dynamic spark tester |
YM-34487 |
90890-06754 |
||||
90890-06754 |
Ignition checker |
||||||
This instrument is necessary for checking the ignition |
|||||||
system components. |
|||||||
ACC-QUICK-GS-KT |
Quick gasket |
ACC-QUICK-GS-KT |
90890-85505 |
||||
90890-85505 |
YAMAHA Bond No. 1215 |
||||||
This sealant (Bond) is used for crankcase mating |
|||||||
surface, etc. |
|||||||
1 — 9
CONTROL FUNCTIONS
EC150000
GEN
INFO
CONTROL FUNCTIONS
MAIN SWITCH
Functions of the respective switch positions are as follows:
ON:
The engine can be started only at this position. OFF:
All electrical circuits are switched off.
Main switch indicator light
The main switch 1 is equipped with an indicator light 2 to avoid forgetting to turn it off. This light functions as follows.
●It lights up with the main switch “ON”.
●It goes out when the engine increases its speed after being started.
●It lights up again when the engine is stopped.
NOTE:
If the indicator light will not light up with the main switch “ON”, it shows a lack of the battery voltage. Recharge the battery. If the engine is kick started, turn off the light switch.
EC151000
“ENGINE STOP” BUTTON
The “ENGINE STOP” button 1 is located on the left handlebar. Continue pushing the “ENGINE STOP” button till the engine comes to a stop.
START SWITCH
The start switch 1 is located on the right handlebar. Push this switch to crank the engine with the starter.
1 — 10
GEN
CONTROL FUNCTIONS INFO
EC152000
CLUTCH LEVER
The clutch lever 1 is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts.
EC153000
SHIFT PEDAL
The gear ratios of the constant-mesh 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal 1 on the left side of the engine.
EC154000
KICKSTARTER
Rotate the kickstarter 1 away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting.
EC155001
THROTTLE GRIP
The throttle grip 1 is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you.
EC156000
FRONT BRAKE LEVER
The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to activate the front brake.
1 — 11
GEN
CONTROL FUNCTIONS INFO
EC157000
REAR BRAKE PEDAL
The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake.
FUEL COCK
The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock has three positions:
OFF:With the lever in this position fuel will not flow. Always return the lever to this position when the engine is not running.
ON: With the lever in this position fuel flows to the carburetor. Normal riding is done with the lever in this position.
RES:With the lever in this position fuel flows to the carburetor from the reserve section of the fuel tank after the main supply of the fuel has been depleted. Normal riding is possible with the lever is in this position, but it is recommended to add fuel as soon as possible.
COLD STARTER KNOB
When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is controlled by the cold starter knob 1, supplies this mixture. Pull the cold starter knob out to open the circuit for starting. When the engine has warmed up, push it in to close the circuit.
HOT STARTER LEVER
The hot starter lever 1 is used when starting a warm engine.
Use the hot starter lever when starting the engine again immediately after it was stopped (the engine is still warm). Pulling the hot starter lever injects secondary air to thin the air-fuel mixture temporarily, allowing the engine to be started more easily.
1 — 12
GEN
CONTROL FUNCTIONS INFO
LIGHTS SWITCH
The lights switch 1 is located on the handlebar.
EC15F000
VALVE JOINT
This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose.
CAUTION:
In this installation, make sure the arrow faces the fuel tank and also downward.
SPARK PLUG WRENCH
This spark plug wrench 1 is used to remove and install the spark plug.
NIPPLE WRENCH
This nipple wrench 1 is used to tighten the spoke.
1 — 13
Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race.
Recommended fuel: Except for ZA:
Premium unleaded gasoline only with a research octane number of 95 or higher.
For ZA:
Premium gasoline
CAUTION:
Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.
NOTE:
If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.
WARNING
●For refueling, be sure to stop the engine and use enough care not to spill any fuel. Also be sure to avoid refueling close to a fire.
●Refuel after the engine, exhaust pipe, etc. have cooled off.
1 — 14
GEN
STARTING AND BREAK-IN INFO
STARTING AND BREAK-IN
WARNING
Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area.
CAUTION:
●The carburetor on this machine has a built-in accelerator pump. Therefore, when starting the engine, do not operate the throttle or the spark plug will foul.
●Unlike a two-stroke engine, this engine cannot be kick started when the throttle is open because the kickstarter may kick back. Also, if the throttle is open the air/ fuel mixture may be too lean for the engine to start.
●Before starting the machine, perform the checks in the pre-operation check list.
AIR FILTER MAINTENANCE
According to “AIR FILTER CLEANING” section in the CHAPTER 3, apply the foam-air-filter oil or its equivalent to the element. (Excess oil in the element may adversely affect engine starting.)
STARTING A COLD ENGINE
NOTE:
This model is equipped with an ignition circuit cut-off system. The engine can be started under the following conditions.
●When the transmission is in neutral.
●When the clutch is disengaged with the transmission in any position. However, it is recommended to shift into neutral before starting the engine.
1.Inspect the coolant level.
2.Turn the fuel cock to “ON”.
3.Push the main switch to “ON”.
4.Shift the transmission into neutral.
5.Fully open the cold starter knob 1.
6.Start the engine by pushing the start switch or by kicking the kickstarter.
1 — 15
GEN
STARTING AND BREAK-IN INFO
NOTE:
If the engine fails to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. If the engine does not start with the starter motor, try using the kickstarter.
WARNING
●If the starter motor will not turn when pushing the start switch, stop pushing it immediately and kick start the engine in order to avoid the load on the motor.
●Do not open the throttle while kicking the kickstarter. Otherwise, the kickstarter may kick back.
7.Return the cold starter knob to its original position and run the engine at 3,000 ~ 5,000 r/min for 1 or 2 minutes.
NOTE:
Since this model is equipped with an accelerator pump, if the engine is raced (the throttle opened and closed), the air/fuel mixture will be too rich and the engine may stall. Also unlike a two-stroke engine, this model can idle.
CAUTION:
Do not warm up the engine for extended periods of time.
1 — 16
GEN
STARTING AND BREAK-IN INFO
STARTING A WARM ENGINE
Do not operate the cold starter knob and throttle. Pull the hot starter lever 1 and start the engine by pushing the start switch or by kicking the kickstarter forcefully with a firm stroke. As soon as the engine starts, release the hot starter lever to close the air passage.
Restarting an engine after a fall
Pull the hot starter lever and start the engine. As soon as the engine starts, release the hot starter lever to close the air passage.
The engine fails to start
Pull the hot starter lever all the way out and while holding the lever, kick the kickstarter 10 to 20 times to clear the engine.
Then, restart the engine.
Refer to “Restarting an engine after a fall”.
Throttle |
Cold |
Hot |
|||
grip oper- |
starter |
starter |
|||
ation* |
knob |
lever |
|||
Air temperature = less than |
Open 3 |
ON |
OFF |
||
engine |
5 ˚C (41 ˚F) |
or 4 times |
|||
Air temperature = more |
None |
ON |
OFF |
||
than 5 ˚C (41 ˚F) |
|||||
cold |
|||||
Air temperature (normal tem- |
|||||
a |
|||||
perature) = between 5 ˚C |
None |
ON/OFF |
OFF |
||
Starting |
|||||
(41 ˚F) and 25 ˚C (77 ˚F) |
|||||
Air temperature = more |
None |
OFF |
OFF |
||
than 25 ˚C (77 ˚F) |
|||||
Starting an engine after a long |
None |
ON |
OFF |
||
period of time |
|||||
Restarting a warm engine |
None |
OFF |
ON |
||
Restarting an engine after a fall |
None |
OFF |
ON |
||
* Operate the throttle grip before kick starting.
CAUTION:
Observe the following break-in procedures during initial operation to ensure optimum performance and avoid engine damage.
1 — 17
GEN
STARTING AND BREAK-IN INFO
BREAK-IN PROCEDURES
1.Before starting the engine, fill the fuel tank with the fuel.
2.Perform the pre-operation checks on the machine.
3.Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “ENGINE STOP” button. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted.
4.Operate the machine in the lower gears at moderate throttle openings for five to eight minutes.
5.Check how the engine runs when the machine is ridden with the throttle 1/4 to 1/2 open (low to medium speed) for about one hour.
6.Restart the engine and check the operation of the machine throughout its entire operating range. Restart the machine and operate it for about 10 to 15 more minutes. The machine will now be ready to race.
CAUTION:
●After the break-in or before each race, you must check the entire machine for loose fittings and fasteners as per “TORQUE-CHECK POINTS”.
Tighten all such fasteners as required.
●When any of the following parts have been replaced, they must be broken in. CYLINDER AND CRANKSHAFT:
About one hour of break-in operation is necessary.
PISTON, RING, VALVES, CAMSHAFTS AND GEARS:
These parts require about 30 minutes of break-in operation at half-throttle or less. Observe the condition of the engine carefully during operation.
1 — 18
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
GEN INFO
Frame construction |
Frame to rear frame |
|||
Combined seat and tank |
Fuel tank to frame |
|||
Exhaust system |
Silencer to rear frame |
|||
Engine mounting |
Frame to engine |
|||
Engine bracket to engine |
||||
Engine bracket to frame |
||||
Steering |
Steering shaft to |
Steering shaft to frame |
||
handlebar |
Steering shaft to handle crown |
|||
Handle crown to handlebar |
||||
Suspension |
Front |
Steering shaft to front |
Front fork to handle crown |
|
fork |
Front fork to under bracket |
|||
Rear |
For link type |
Assembly of links |
||
Link to frame |
||||
Link to shock absorber |
||||
Link to swingarm |
||||
Rear |
Installation of shock |
Shock absorber to frame |
||
absorber |
||||
Rear |
Installation of swing- |
Tightening of pivot shaft |
||
arm |
||||
Wheel |
Installation of wheel |
Front |
Tightening of front axle |
|
Tightening of axle holder |
||||
Rear |
Tightening of rear axle |
|||
Wheel to sprocket |
||||
Brake |
Front |
Caliper to front fork |
||
Brake disc to wheel |
||||
Tightening of union bolt |
||||
Master cylinder to handlebar |
||||
Tightening of air bleeder |
||||
Rear |
Brake pedal to frame |
|||
Brake disc to wheel |
||||
Tightening of union bolt |
||||
Master cylinder to frame |
||||
Tightening of air bleeder |
||||
Fuel system |
Fuel tank to fuel cock |
|||
Lubrication system |
Tightening of oil hose clamp |
NOTE:
Concerning the tightening torque, refer to “MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.
1 — 19
CLEANING AND STORAGE
EC1B0000
GEN INFO
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components.
1.Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose.
2.If the engine is excessively greasy, apply some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles.
3.Rinse the dirt and degreaser off with a garden hose; use only enough pressure to do the job.
CAUTION:
Excessive hose pressure may cause water seepage and contamination of wheel bearings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers.
4.After the majority of the dirt has been hosed off, wash all surfaces with warm water and a mild detergent. Use an old toothbrush to clean hard-to-reach places.
5.Rinse the machine off immediately with clean water, and dry all surfaces with a soft towel or cloth.
6.Immediately after washing, remove excess water from the chain with a paper towel and lubricate the chain to prevent rust.
7.Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.
1 — 20
GEN
CLEANING AND STORAGE INFO
8.Automotive wax may be applied to all painted or chromed surfaces. Avoid combination cleaner-waxes, as they may contain abrasives.
9.After completing the above, start the engine and allow it to idle for several minutes.
EC1B2001
STORAGE
If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows:
1.Drain the fuel tank, fuel lines, and the carburetor float bowl.
2.Remove the spark plug, pour a tablespoon of SAE 10W-30 motor oil in the spark plug hole, and reinstall the plug. With the engine stop switch pushed in, kick the engine over several times to coat the cylinder walls with oil.
3.Remove the drive chain, clean it thoroughly with solvent, and lubricate it. Reinstall the chain or store it in a plastic bag tied to the frame.
4.Lubricate all control cables.
5.Block the frame up to raise the wheels off the ground.
6.Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.
7.If the machine is to be stored in a humid or salt-air environment, coat all exposed metal surfaces with a film of light oil. Do not apply oil to rubber parts or the seat cover.
NOTE:
Make any necessary repairs before the machine is stored.
1 — 21
GENERAL SPECIFICATIONS SPEC
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: |
WR450FR (USA) |
||||||||||||||||||
WR450F (EUROPE) |
|||||||||||||||||||
WR450F(R) (CDN, AUS, NZ, ZA) |
|||||||||||||||||||
Model code number: |
5TJ1 (USA) |
||||||||||||||||||
5TJ2 (EUROPE) |
|||||||||||||||||||
5TJ4 (CDN, AUS, NZ, ZA) |
|||||||||||||||||||
Dimensions: |
|||||||||||||||||||
Overall length |
2,171 mm (85.5 in) |
||||||||||||||||||
Overall width |
827 mm (32.6 in) |
||||||||||||||||||
Overall height |
1,303 mm (51.3 in) |
||||||||||||||||||
Seat height |
998 mm (39.3 in) |
||||||||||||||||||
Wheelbase |
1,485 mm (58.5 in) |
||||||||||||||||||
Minimum ground clearance |
371 mm (14.6 in) |
||||||||||||||||||
Basic weight: |
|||||||||||||||||||
With oil and full fuel tank |
122 kg (269 lb) |
||||||||||||||||||
Engine: |
|||||||||||||||||||
Engine type |
Liquid cooled 4-stroke, DOHC |
||||||||||||||||||
Cylinder arrangement |
Single cylinder, forward inclined |
||||||||||||||||||
Displacement |
449 cm3 (15.8 Imp oz, 15.2 US oz) |
||||||||||||||||||
Bore × stroke |
95.0 × 63.4 mm (3.74 × 2.50 in) |
||||||||||||||||||
Compression ratio |
12.5 : 1 |
||||||||||||||||||
Starting system |
Kick and electric starter |
||||||||||||||||||
Lubrication system: |
Dry sump |
||||||||||||||||||
Oil type or grade: |
|||||||||||||||||||
Engine oil |
(For USA and CDN) |
||||||||||||||||||
At 5 ˚C (40 ˚F) or higher Å |
|||||||||||||||||||
Yamalube 4 (20W-40) or SAE 20W-40 type SG |
|||||||||||||||||||
motor oil (Non-Friction modified) |
|||||||||||||||||||
At 15 ˚C (60 ˚F) or lower ı |
|||||||||||||||||||
Yamalube 4 (10W-30) or SAE 10W-30 type SG |
|||||||||||||||||||
motor oil (Non-Friction modified) and/or |
|||||||||||||||||||
Yamalube 4-R (15W-50) (Non-Friction modi- |
|||||||||||||||||||
fied) |
|||||||||||||||||||
(Except for USA and CDN) |
|||||||||||||||||||
Temp. |
°C |
||||||||||||||||||
API “SG” or higher grade |
|||||||||||||||||||
-20 |
-10 |
0 |
10 |
20 |
30 |
40 |
50 |
||||||||||||
10W-30 |
|||||||||||||||||||
10W-40 |
|||||||||||||||||||
15W-40 |
|||||||||||||||||||
20W-40 |
|||||||||||||||||||
20W-50 |
|||||||||||||||||||
-4 |
14 |
30 |
50 |
68 |
86 |
104 |
122 °F |
||||||||||||
2 — 1 |
GENERAL SPECIFICATIONS |
SPEC |
||||
Oil capacity: |
|||||
Engine oil |
|||||
Periodic oil change |
1.0 L (0.88 Imp qt, 1.06 US qt) |
||||
With oil filter replacement |
1.1 L (0.97 Imp qt, 1.16 US qt) |
||||
Total amount |
1.2 L (1.06 Imp qt, 1.27 US qt) |
||||
Coolant capacity (including all routes): |
1.6 L (1.41 Imp qt, 1.69 US qt) |
||||
Air filter: |
Wet type element |
||||
Fuel: |
|||||
Type |
Premium unleaded gasoline only with a research |
||||
octane number of 95 or higher.(Except for ZA) |
|||||
Premium gasoline (For ZA) |
|||||
Tank capacity |
10 L (2.2 Imp gal, 2.64 US gal) |
||||
Reserve |
1.2 L (0.26 Imp gal, 0.32 US gal) |
||||
Carburetor: |
|||||
Type |
FCR MX39 |
||||
Manufacturer |
KEIHIN |
||||
Spark plug: |
|||||
Type/manufacturer |
CR8E/NGK (resistance type) |
||||
Gap |
0.7 ~ 0.8 mm (0.028 ~ 0.031 in) |
||||
Clutch type: |
Wet, multiple-disc |
||||
Transmission: |
|||||
Primary reduction system |
Gear |
||||
Primary reduction ratio |
62/22 (2.818) |
||||
Secondary reduction system |
Chain drive |
||||
Secondary reduction ratio |
50/14 (3.571) |
||||
Transmission type |
Constant mesh, 5-speed |
||||
Operation |
Left foot operation |
||||
Gear ratio: 1st |
29/12 (2.416) |
||||
2nd |
26/15 (1.733) |
||||
3rd |
21/16 (1.312) |
||||
4th |
21/20 (1.050) |
||||
5th |
21/25 (0.840) |
||||
Chassis: |
|||||
Frame type |
Semi double cradle |
||||
Caster angle |
27.2˚ |
||||
Trail |
118 mm (4.65 in) |
||||
Tire: |
|||||
Type |
With tube |
||||
Size (front) |
80/100-21 51M (USA, CDN, ZA) |
||||
90/90-21 54R (EUROPE, AUS, NZ) |
|||||
Size (rear) |
110/100-18 64M (USA, CDN, ZA) |
||||
130/90-18 69R (EUROPE, AUS, NZ) |
|||||
Tire pressure (front and rear) |
100 kPa (1.0 kgf/cm2, 15 psi) |
2 — 2
GENERAL SPECIFICATIONS |
SPEC |
|||||
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 |
|||||
Generator system |
AC magneto |
|||||
Battery type |
YTZ7S |
|||||
Battery voltage/capacity |
12 V/6 AH |
|||||
Specific gravity |
1.310 |
|||||
Headlight type: |
Quartz bulb (halogen) |
|||||
Bulb wattage × quantity: |
||||||
Headlight |
12 V 60/55 W × 1 |
|||||
Taillight |
12 V 21/5 W × 1 |
2 — 3
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item |
Standard |
Limit |
|||
Cylinder head: |
|||||
Warp limit |
—- |
0.05 mm |
|||
(0.002 in) |
|||||
Cylinder: |
||||
Bore size |
95.00 ~ 95.01 mm |
—- |
||
(3.7402 ~ 3.7406 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 journal diameter |
21.967 ~ 21.980 mm |
—- |
||
(0.8648 ~ 0.8654 in) |
||||
Shaft-to-cap clearance |
0.020 ~ 0.054 mm |
0.08 mm |
||
(0.0008 ~ 0.0021 in) |
(0.003 in) |
|||
Cam dimensions |
||||
A
B |
||||||||||||||
Intake |
“A” |
31.200 ~ 31.300 mm |
31.100 mm |
|||||||||||
(1.2283 ~ 1.2323 in) |
(1.2244 in) |
|||||||||||||
“B” |
22.550 ~ 22.650 mm |
22.450 mm |
||||||||||||
(0.8878 ~ 0.8917 in) |
(0.8839 in) |
|||||||||||||
Exhaust |
“A” |
30.950 ~ 31.050 mm |
30.850 mm |
|||||||||||
(1.2185 ~ 1.2224 in) |
(1.2146 in) |
|||||||||||||
“B” |
22.494 ~ 22.594 mm |
22.394 mm |
||||||||||||
(0.8856 ~ 0.8895 in) |
(0.8817 in) |
|||||||||||||
Camshaft runout limit |
—- |
0.03 mm |
||||||||||||
(0.0012 in) |
||||||||||||||
2 — 4
MAINTENANCE SPECIFICATIONS |
SPEC |
||||||||||||||||||||||||||||
Item |
Standard |
Limit |
|||||||||||||||||||||||||||
Cam chain: |
|||||||||||||||||||||||||||||
Cam chain type/No. of links |
98XRH2010-118M/118 |
—- |
|||||||||||||||||||||||||||
Cam chain adjustment method |
Automatic |
—- |
|||||||||||||||||||||||||||
Valve, valve seat, valve guide: |
|||||||||||||||||||||||||||||
Valve clearance (cold) |
IN |
0.10 ~ 0.15 mm |
—- |
||||||||||||||||||||||||||
(0.0039 ~ 0.0059 in) |
|||||||||||||||||||||||||||||
EX |
0.20 ~ 0.25 mm |
—- |
|||||||||||||||||||||||||||
(0.0079 ~ 0.0098 in) |
|||||||||||||||||||||||||||||
Valve dimensions: |
|||||||||||||||||||||||||||||
B |
C |
||||||||||||||||||||||||||||
A |
Seat Width |
D |
|||||||||||||||||||||||||||
Margin Thickness |
|||||||||||||||||||||||||||||
Head Diameter |
Face Width |
||||||||||||||||||||||||||||
“A” head diameter |
IN |
26.9 ~ 27.1 mm |
—- |
||||||||||||||||||||||||||
(1.0591 ~ 1.0669 in) |
|||||||||||||||||||||||||||||
EX |
27.9 ~ 28.1 mm |
—- |
|||||||||||||||||||||||||||
(1.0984 ~ 1.1063 in) |
|||||||||||||||||||||||||||||
“B” face width |
IN |
2.26 mm (0.089 in) |
—- |
||||||||||||||||||||||||||
EX |
2.26 mm (0.089 in) |
—- |
|||||||||||||||||||||||||||
“C” seat width |
IN |
0.9 ~ 1.1 mm |
1.6 mm |
||||||||||||||||||||||||||
(0.0354 ~ 0.0433 in) |
(0.0630 in) |
||||||||||||||||||||||||||||
EX |
0.9 ~ 1.1 mm |
1.6 mm |
|||||||||||||||||||||||||||
(0.0354 ~ 0.0433 in) |
(0.0630 in) |
||||||||||||||||||||||||||||
“D” margin thickness |
IN |
1 mm (0.0394 in) |
0.85 mm |
||||||||||||||||||||||||||
(0.033 in) |
|||||||||||||||||||||||||||||
EX |
1 mm (0.0394 in) |
0.85 mm |
|||||||||||||||||||||||||||
(0.033 in) |
|||||||||||||||||||||||||||||
Stem outside diameter |
IN |
4.475 ~ 4.490 mm |
4.445 mm |
||||||||||||||||||||||||||
(0.1762 ~ 0.1768 in) |
(0.1750 in) |
||||||||||||||||||||||||||||
EX |
4.965 ~ 4.980 mm |
4.935 mm |
|||||||||||||||||||||||||||
(0.1955 ~ 0.1961 in) |
(0.1943 in) |
||||||||||||||||||||||||||||
Guide inside diameter |
IN |
4.500 ~ 4.512 mm |
4.550 mm |
||||||||||||||||||||||||||
(0.1772 ~ 0.1776 in) |
(0.1791 in) |
||||||||||||||||||||||||||||
EX |
5.000 ~ 5.012 mm |
5.050 mm |
|||||||||||||||||||||||||||
(0.1969 ~ 0.1973 in) |
(0.1988 in) |
||||||||||||||||||||||||||||
Stem-to-guide clearance |
IN |
0.010 ~ 0.037 mm |
0.08 mm |
||||||||||||||||||||||||||
(0.0004 ~ 0.0015 in) |
(0.003 in) |
||||||||||||||||||||||||||||
EX |
0.020 ~ 0.047 mm |
0.10 mm |
|||||||||||||||||||||||||||
(0.0008 ~ 0.0019 in) |
(0.004 in) |
||||||||||||||||||||||||||||
Stem runout limit |
—- |
0.01 mm |
|||||||||||||||||||||||||||
(0.0004 in) |
|||||||||||||||||||||||||||||
2 — 5
MAINTENANCE SPECIFICATIONS SPEC
Item |
Standard |
Limit |
||
Valve spring: |
||||
Free length |
IN |
37.03 mm (1.46 in) |
35.17 mm |
|
(1.38 in) |
||||
EX |
37.68 mm (1.48 in) |
35.79 mm |
||
(1.41 in) |
||||
Set length (valve closed) |
IN |
27.87 mm (1.10 in) |
—- |
|
EX |
27.38 mm (1.08 in) |
—- |
||
Compressed force |
||||
(installed) |
IN |
111.3 ~ 127.9 N at 27.87 mm |
—- |
|
(11.3 ~ 13.0 kg at 27.87 mm, |
||||
24.91 ~ 28.66 lb at 1.10 in) |
||||
EX |
127.4 ~ 146.4 N at 27.38 mm |
—- |
||
(13.0 ~ 14.9 kg at 27.38 mm, |
||||
Tilt limit* |
28.66 ~ 32.85 lb at 1.08 in) |
|||
IN |
—- |
2.5˚/ 1.61 mm |
||
(2.5˚/0.063 in) |
||||
EX |
—- |
2.5˚/1.65 mm |
||
(2.5˚/0.065 in) |
||||
Direction of winding |
||||||
(top view) |
IN |
Clockwise |
—- |
|||
EX |
Clockwise |
—- |
||||
Piston: |
||||||
Piston to cylinder clearance |
0.040 ~ 0.065 mm |
0.1 mm |
||||
(0.0016 ~ 0.0026 in) |
(0.004 in) |
|||||
Piston size “D” |
94.945 ~ 94.960 mm |
—- |
||||
(3.738 ~ 3.739 in) |
||||||
H |
||||||
D |
||||
Measuring point “H” |
8 mm (0.315 in) |
—- |
||
Piston off-set |
1 mm (0.0394 in) |
—- |
||
Piston pin bore inside diameter |
18.004 ~ 18.015 mm |
18.045 mm |
||
(0.7088 ~ 0.7093 in) |
(0.7104 in) |
|||
Piston pin outside diameter |
17.991 ~ 18.000 mm |
17.971 mm |
||
(0.7083 ~ 0.7087 in) |
(0.7075 in) |
2 — 6
MAINTENANCE SPECIFICATIONS SPEC
Item |
Standard |
Limit |
|||||||||||||||||
Piston rings: |
|||||||||||||||||||
Top ring: |
|||||||||||||||||||
B |
|||||||||||||||||||
Type |
T |
Barrel |
—- |
||||||||||||||||
Dimensions (B × T) |
1.2 × 3.5 mm (0.05 × 0.14 in) |
—- |
|||||||||||||||||
End gap (installed) |
0.20 ~ 0.30 mm |
0.55 mm |
|||||||||||||||||
(0.008 ~ 0.012 in) |
(0.022 in) |
||||||||||||||||||
Side clearance (installed) |
0.030 ~ 0.065 mm |
0.12 mm |
|||||||||||||||||
(0.0012 ~ 0.0026 in) |
(0.005 in) |
||||||||||||||||||
2nd ring: |
|||||||||||||||||||
B |
|||||||||||||||||||
Type |
T |
Taper |
—- |
||||||||||||||||
Dimensions (B × T) |
1.00 × 3.35 mm (0.04 × 0.13 in) |
—- |
|||||||||||||||||
End gap (installed) |
0.35 ~ 0.50 mm |
0.85 mm |
|||||||||||||||||
(0.014 ~ 0.020 in) |
(0.033 in) |
||||||||||||||||||
Side clearance |
0.020 ~ 0.055 mm |
0.12 mm |
|||||||||||||||||
(0.0008 ~ 0.0022 in) |
(0.005 in) |
||||||||||||||||||
Oil ring: |
|||||||||||||||||||
B |
|||||||||||||||||||
T |
|||||||||||||||||||
Dimensions (B × T) |
2.0 × 2.9 mm (0.08 × 0.11 in) |
—- |
|||||||||||||||||
End gap (installed) |
0.2 ~ 0.5 mm (0.01 ~ 0.02 in) |
—- |
|||||||||||||||||
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 |
0.50 mm |
|||||||||||||||||
(0.0059 ~ 0.0177 in) |
(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 |
—- |
2 — 7
MAINTENANCE SPECIFICATIONS SPEC
Item |
Standard |
Limit |
|||
Clutch: |
|||||
Friction plate thickness |
2.92 ~ 3.08 mm |
2.8 mm |
|||
(0.115 ~ 0.121 in) |
(0.110 in) |
||||
Quantity |
9 |
—- |
|||
Clutch plate thickness |
1.1 ~ 1.3 mm (0.043 ~ 0.051 in) |
—- |
|||
Quantity |
8 |
—- |
|||
Warp limit |
—- |
0.1 mm |
|||
(0.004 in) |
|||||
Clutch spring free length |
48.4 mm (1.91 in) |
47.4 mm |
|||
(1.87 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 |
Ratchet type |
—- |
|||
Carburetor: |
EUROPE, |
||||
USA |
CDN, AUS, NZ, |
||||
ZA |
|||||
I. D. mark |
—- |
||||
5TJ1 00 |
5TJ2 10 |
||||
Main jet |
(M.J) |
#150 |
#160 |
—- |
|
Main air jet |
(M.A.J) |
ø2.0 |
← |
—- |
|
Jet needle — clip position |
(J.N) |
OBDUT-4 |
OBDUQ-4 |
—- |
|
Cutaway |
(C.A) |
1.5 |
← |
—- |
|
Pilot jet |
(P.J) |
#45 |
#48 |
—- |
|
Pilot air jet |
(P.A.J) |
#70 |
#80 |
—- |
|
Pilot outlet |
(P.O) |
ø0.9 |
← |
—- |
|
Pilot screw (example) |
(P.S) |
1-3/4 |
1-1/2 |
—- |
|
Bypass |
(B.P) |
ø1.0 |
← |
—- |
|
Valve seat size |
(V.S) |
ø3.8 |
← |
—- |
|
Starter jet |
(G.S) |
#65 |
← |
—- |
|
Leak jet |
(Acc.P) |
#70 |
#50 |
—- |
|
Float height |
(F.H) |
8 mm (0.31 in) |
← |
—- |
|
Engine idle speed |
1,700 ~ |
← |
—- |
||
1,900 r/min |
|||||
Intake vacuum |
33.3 ~ 38.7 kPa |
← |
—- |
||
(250 ~ 290 mmHg, |
|||||
9.84 ~ 11.42 inHg) |
|||||
Hot starter lever free play |
3 ~ 6 mm |
← |
—- |
||
(0.12 ~ 0.24 in) |
2 — 8
MAINTENANCE SPECIFICATIONS SPEC
Item |
Standard |
Limit |
Lubrication system: |
||
Oil filter type |
Paper type |
—- |
Oil pump type |
Trochoid type |
—- |
Tip clearance “A” |
0.12 mm or less |
0.20 mm |
(0.0047 in or less) |
(0.008 in) |
|
Tip clearance “B” |
0.09 ~ 0.17 mm |
0.24 mm |
(0.0035 ~ 0.0067 in) |
(0.009 in) |
|
Side clearance |
0.03 ~ 0.10 mm |
0.17 mm |
(0.0012 ~ 0.0039 in) |
(0.007 in) |
|
Bypass valve setting pressure |
40 ~ 80 kPa (0.4 ~ 0.8 kg/cm2, |
—- |
5.69 ~ 11.38 psi) |
||
Cooling: |
||
Radiator core size |
||
Width |
127.8 mm (5.0 in) |
—- |
Height |
260 mm (10.2 in) |
—- |
Thickness |
32 mm (1.26 in) |
—- |
Radiator cap opening pressure |
110 kPa (1.1 kg/cm2, 15.6 psi) |
—- |
Radiator capacity (total) |
0.78 L (0.69 Imp qt, 0.82 US qt) |
—- |
Water pump |
||
Type |
Single-suction centrifugal pump |
—- |
2 — 9
MAINTENANCE SPECIFICATIONS |
SPEC |
|
Item |
Standard |
|
Lubrication chart: |
||
Pressure feed |
Oil tank |
|
Splashed scavenge |
||
Camshaft |
||
Cylinder head |
Valve lifter |
|
Piston |
||
Transmission gears |
||
Piston pin |
||
Main axle |
||
Oil filter |
Crank pin |
|
Drive axle |
||
Check ball |
||
Oil pump rotor 1 |
||
Oil pump rotor 2 |
||
Oil strainer |
||
Oil pan |
2 — 10
MAINTENANCE SPECIFICATIONS |
SPEC |
||||||||||
Part to be tightened |
Thread size |
Q’ty |
Tightening torque |
||||||||
Nm |
m·kg |
ft·lb |
|||||||||
Spark plug |
M10S × 1.0 |
1 |
13 |
1.3 |
9.4 |
||||||
Camshaft cap |
M6 |
× 1.0 |
10 |
10 |
1.0 |
7.2 |
|||||
Cylinder head blind plug screw |
M12 × 1.0 |
1 |
37 |
3.7 |
27 |
||||||
Cylinder head (stud bolt) |
M6 |
× 1.0 |
2 |
7 |
0.7 |
5.1 |
|||||
M8 × 1.25 |
1 |
15 |
1.5 |
11 |
|||||||
(bolt) |
M10 |
× 1.25 |
4 |
Refer to NOTE.*1 |
|||||||
(nut) |
M6 |
× 1.0 |
2 |
10 |
7.2 |
||||||
1.0 |
|||||||||||
Cylinder head cover |
M6 |
× 1.0 |
2 |
10 |
1.0 |
7.2 |
|||||
Cylinder |
M6 |
× 1.0 |
1 |
10 |
1.0 |
7.2 |
|||||
Timing chain tensioner |
M6 |
× 1.0 |
2 |
10 |
1.0 |
7.2 |
|||||
Tensioner cap bolt |
M6 |
× 1.0 |
1 |
7 |
0.7 |
5.1 |
|||||
Timing chain guide (rear) |
M6 |
× 1.0 |
2 |
10 |
1.0 |
7.2 |
|||||
Exhaust pipe (nut) |
M8 × 1.25 |
1 |
13 |
1.3 |
9.4 |
||||||
(bolt) |
M8 × 1.25 |
1 |
24 |
2.4 |
17 |
||||||
Silencer |
M8 × 1.25 |
2 |
35 |
3.5 |
25 |
||||||
Silencer clamp |
M8 × 1.25 |
1 |
20 |
2.0 |
14 |
||||||
Exhaust pipe protector |
M6 |
× 1.0 |
3 |
10 |
1.0 |
7.2 |
|||||
Spark arrester (for USA) |
M6 |
× 1.0 |
3 |
10 |
1.0 |
7.2 |
|||||
Silencer end pipe (for USA) |
M6 |
× 1.0 |
1 |
10 |
1.0 |
7.2 |
|||||
Carburetor joint clamp (cylinder head side) |
M5 |
× 0.8 |
1 |
3 |
0.3 |
2.2 |
|||||
Carburetor joint clamp (carburetor side) |
M4 |
× 0.7 |
1 |
3 |
0.3 |
2.2 |
|||||
Air filter case |
M6 |
× 1.0 |
2 |
8 |
0.8 |
5.8 |
|||||
Air filter joint clamp |
M6 |
× 1.0 |
1 |
3 |
0.3 |
2.2 |
|||||
Air filter joint and air filter case |
M5 |
× 0.8 |
1 |
4 |
0.4 |
2.9 |
|||||
Throttle cable (pull) |
M6 |
× 1.0 |
1 |
4 |
0.4 |
2.9 |
|||||
Throttle cable (return) |
M12 × 1.0 |
1 |
11 |
1.1 |
8.0 |
||||||
Throttle cable cover |
M5 |
× 0.8 |
2 |
4 |
0.4 |
2.9 |
|||||
Hot starter plunger |
M12 × 1.0 |
1 |
2 |
0.2 |
1.4 |
||||||
Radiator panel (upper) |
M6 |
× 1.0 |
2 |
10 |
1.0 |
7.2 |
|||||
Radiator |
M6 |
× 1.0 |
6 |
10 |
1.0 |
7.2 |
|||||
Radiator hose clamp |
M6 |
× 1.0 |
8 |
2 |
0.2 |
1.4 |
|||||
Radiator pipe 1, 2 |
M10 × 1.0 |
2 |
10 |
1.0 |
7.2 |
||||||
Impeller |
M8 × 1.25 |
1 |
14 |
1.4 |
10 |
||||||
Water pump housing cover |
M6 |
× 1.0 |
3 |
10 |
1.0 |
7.2 |
|||||
Coolant drain bolt |
M6 |
× 1.0 |
1 |
10 |
1.0 |
7.2 |
|||||
Oil pump cover |
M4 |
× 0.7 |
1 |
2 |
0.2 |
1.4 |
|||||
Oil pump |
M6 |
× 1.0 |
3 |
10 |
1.0 |
7.2 |
|||||
Engine oil drain bolt (oil filter) |
M6 |
× 1.0 |
1 |
10 |
1.0 |
7.2 |
|||||
Oil filter cover |
M6 |
× 1.0 |
2 |
10 |
1.0 |
7.2 |
|||||
Oil delivery pipe 1 |
M10 |
× 1.25 |
1 |
20 |
2.0 |
14 |
|||||
M8 × 1.25 |
2 |
18 |
1.8 |
13 |
|||||||
Oil delivery pipe 2 |
M6 |
× 1.0 |
1 |
10 |
1.0 |
7.2 |
|||||
Oil hose |
M6 |
× 1.0 |
2 |
10 |
1.0 |
7.2 |
|||||
2 — 11 |
MAINTENANCE SPECIFICATIONS |
SPEC |
|||||||||
Part to be tightened |
Thread size |
Q’ty |
Tightening torque |
|||||||
Nm |
m·kg |
ft·lb |
||||||||
Oil check bolt |
M6 |
× 1.0 |
1 |
10 |
1.0 |
7.2 |
||||
Oil hose clamp |
– |
2 |
2 |
0.2 |
1.4 |
|||||
Clutch cover |
M6 |
× 1.0 |
7 |
10 |
1.0 |
7.2 |
||||
Crankcase cover (right) |
M6 |
× 1.0 |
10 |
10 |
1.0 |
7.2 |
||||
Crankcase cover (left) |
M6 |
× 1.0 |
9 |
10 |
1.0 |
7.2 |
||||
Idle gear cover (starter motor) |
M6 |
× 1.0 |
2 |
10 |
1.0 |
7.2 |
||||
Crankcase |
M6 |
× 1.0 |
12 |
12 |
1.2 |
8.7 |
||||
Clutch cable holder |
M6 |
× 1.0 |
1 |
10 |
1.0 |
7.2 |
||||
Oil drain bolt (crankcase rear) |
M10 |
× 1.25 |
1 |
20 |
2.0 |
14 |
||||
(crankcase left) |
M6 |
× 1.0 |
1 |
10 |
1.0 |
7.2 |
||||
Oil drain bolt (frame) |
M8 × 1.25 |
1 |
23 |
2.3 |
17 |
|||||
Oil strainer (frame) |
M18 × 1.5 |
1 |
90 |
9.0 |
65 |
|||||
Crankcase bearing stopper |
M6 |
× 1.0 |
15 |
10 |
1.0 |
7.2 |
||||
Drive axle oil seal stopper |
M6 |
× 1.0 |
2 |
10 |
1.0 |
7.2 |
||||
Ratchet wheel guide |
M6 |
× 1.0 |
2 |
12 |
1.2 |
8.7 |
||||
Stopper plate |
M6 |
× 1.0 |
2 |
12 |
1.2 |
8.7 |
||||
Kickstarter |
M8 × 1.25 |
1 |
33 |
3.3 |
24 |
|||||
Screw (kickstarter) |
M6 |
× 1.0 |
1 |
7 |
0.7 |
5.1 |
||||
Starter clutch |
M6 |
× 1.0 |
6 |
16 |
1.6 |
11 |
||||
Primary drive gear |
M20 × 1.0 |
1 |
75 |
7.5 |
54 |
|||||
Clutch boss |
M20 × 1.0 |
1 |
75 |
7.5 |
54 |
|||||
Push lever |
M6 |
× 1.0 |
1 |
10 |
1.0 |
7.2 |
||||
Clutch spring |
M6 |
× 1.0 |
6 |
8 |
0.8 |
5.8 |
||||
Balancer driven gear |
M14 × 1.0 |
1 |
50 |
5.0 |
36 |
|||||
Balancer weight plate |
M6 |
× 1.0 |
3 |
10 |
1.0 |
7.2 |
||||
Drive sprocket |
M20 × 1.0 |
1 |
75 |
7.5 |
54 |
|||||
Drive sprocket cover |
M6 |
× 1.0 |
2 |
8 |
0.8 |
5.8 |
||||
Shift pedal |
M6 |
× 1.0 |
1 |
12 |
1.2 |
8.7 |
||||
Shift guide |
M6 |
× 1.0 |
2 |
10 |
1.0 |
7.2 |
||||
Stopper lever |
M6 |
× 1.0 |
1 |
10 |
1.0 |
7.2 |
||||
Segment |
M8 × 1.25 |
1 |
30 |
3.0 |
22 |
NOTE:
— marked portion shall be checked for torque tightening after break-in or before each race.
NOTE:
*1: Tighten the cylinder head bolts to 30 Nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m · kg, 14 ft · lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 180˚ in the proper tightening sequence.
2 — 12
MAINTENANCE SPECIFICATIONS SPEC
EC212201
CHASSIS
Item |
Standard |
Limit |
||
Steering system: |
||||
Steering bearing type |
Taper roller bearing |
—- |
||
Front suspension: |
USA, CDN |
EUROPE |
AUS, NZ, ZA |
|
Front fork travel |
300 mm (11.8 in) |
← |
← |
|
Fork spring free length |
460 mm (18.1 in) |
← |
← |
|
Spring rate, STD |
K = 4.51 N/mm |
K = 4.12 N/mm |
K = 4.31 N/mm |
|
(0.46 kg/mm, |
(0.42 kg/mm, |
(0.44 kg/mm, |
||
25.8 lb/in) |
23.5 lb/in) |
24.6 lb/in) |
||
Optional spring/spacer |
Yes |
← |
← |
|
Oil capacity |
573 cm3 |
← |
← |
|
(20.2 lmp oz, |
||||
19.4 US oz) |
||||
Oil level |
130 mm (5.12 in) |
← |
← |
|
<Min.~Max.> |
80 ~ 150 mm |
← |
← |
|
(From top of outer tube with inner |
(3.15 ~ 5.91 in) |
|||
tube and damper rod fully com- |
||||
pressed without spring.) |
||||
Oil grade |
Suspension oil |
← |
← |
|
“01” |
||||
Inner tube outer diameter |
46 mm (1.81 in) |
← |
← |
|
Front fork top end |
Zero mm (Zero in) |
← |
← |
|
Rear suspension: |
USA, CDN |
EUROPE |
AUS, NZ, ZA |
|
Shock absorber travel |
132 mm (5.20 in) |
← |
← |
|
Spring free length |
260 mm (10.24 in) |
← |
← |
|
Fitting length |
246 mm (9.69 in) |
246.5 mm (9.70 in) |
← |
|
<Min.~Max.> |
240.5 ~ 258.5 mm |
← |
← |
|
(9.47 ~ 10.18 in) |
||||
Spring rate, STD |
K = 51.0 N/mm |
K = 48.0 N/mm |
K = 52.0 N/mm |
|
(5.20 kg/mm, |
(4.90 kg/mm, |
(5.30 kg/mm, |
||
291.2 lb/in) |
274.4 lb/in) |
296.8 lb/in) |
||
Optional spring |
Yes |
← |
← |
|
Enclosed gas pressure |
1,000 kPa |
← |
← |
|
(10 kg/cm2, 142 psi) |
||||
Swingarm: |
||||
Swingarm free play limit |
||||
End |
—- |
1.0 mm |
||
(0.04 in) |
2 — 13
Loading…
GENERAL TORQUE SPECIFICATIONS. This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached.
Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.