Yamaha DT125REX User Manual

DT125RE

DT125X

2005

1D01-AE1

SERVICE MANUAL

EAS00001

DT125RE/X 1D01-1D02/2C81 SERVICE MANUAL

© 2005 Yamaha Motor España, S.A. 1st Edition, January 2005

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor España, S.A. is expressly prohibited.

Printed in Spain.

EAS00002

NOTICE

This manual was produced by the Yamaha Motor España S.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.

Yamaha Motor España S.A is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

TECHNICAL PUBLICATIONS

YAMAHA MOTOR ESPAÑA, S.A.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

t	The Safety Alert Symbol means ATTENTION! BECOME ALERT!
	YOUR SAFETY IS INVOLVED!
s WARNING	Failure to follow WARNING instructions could result in severe injury
	or death to the motorcycle operator, a bystander or a person chec-
	king or repairing the motorcycle.

CAUTION

NOTE :

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter.

Refer to “SYMBOLS”.

Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the subsection title(s) appears.

Sub-section titles appear in smaller print than the section title.

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.

Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

Jobs requiring more information (such as special tools and technical data) are described sequentially.

GEN		SPEC
INFO
CHK		CHAS
ADJ
ENG		COOL
CARB		ELEC
		10
TRBL
SHTG
11		12
13		14
15	16	17
18	19	20
21	22	23
24		25
		New

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SYMBOLS

The following symbols are not relevant to every vehicle.

Symbols to indicate the subject of each chapter.

General informationSpecifications

Periodic checks and adjustmentsChassis

Engine

Cooling system

Carburetor(s) Electrical system

Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted11 Filling fluid

12 Lubricant13 Special tool

14 Tightening torque15 Wear limit, clearance16 Engine speed

17 Electrical data

Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.

18 Engine oil19 Gear oil

20 Molybdenum-disulfide oil21 Wheel-bearing grease

22 Lithium-soap- based grease23 Molybdenum-disulfide grease

Symbols 24 to 25 in the exploded diagrams indicate the following.

24 Apply locking agent (LOCTITE®)25 Replace the part

EAS00010

TABLE OF CONTENTS

GENERAL INFORMATION

GEN INFO

1

SPECIFICATIONS	SPEC	2
PERIODIC CHECKS AND		3
ADJUSTMENTS	CHK
	ADJ
CHASSIS	CHAS	4
ENGINE	ENG	5
COOLING SYSTEM	COOL	6
CARBURETOR	CARB	7
ELECTRICAL SYSTEM	ELEC	8

TROUBLESHOOTING

TRBL SHTG

9

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION ……………………………………………1-1 FRAME SERIAL NUMBER ……………………………………………………1-1 ENGINE SERIAL NUMBER……………………………………………………1-1

IMPORTANT INFORMATION …………………………………………………1-2 PREPARATION FOR REMOVAL ……………………………………………1-2 ALL REPLACEMENT PARTS …………………………………………………1-2 GASKETS, OIL SEALS AND O-RINGS ……………………………………1-2 LOCK WASHERS/PLATES AND COTTER PINS……………………………1-2 BEARINGS AND OIL SEALS …………………………………………………1-3 CIRCLIP …………………………………………………………………………1-3 CHECKING THE CONNECTIONS……………………………………………1-4

SPECIAL TOOLS …………………………………………………………………1-5

MOTORCYCLE IDENTIFICATIONS						GEN
						INFO
		EAS00014
		GENERAL INFORMATION
		MOTORCYCLE IDENTIFICATION
		FRAME SERIAL NUMBER
		The frame IDENTIFICATION number is
		stamped onto the steering head pipe.
		NOTE:
		The frame serial number is used to identify the
		motorcycle and therefore it can be used for the
		enrollment in the face of the competent autho-
		rity.

ENGINE SERIAL NUMBER

The engine serial number is stamped onto the left side of the crankcase.

NOTE:

The first three digits of this number identifies “the model; the other digits indicate the number” of production of the unit.

NOTE:

Design and specifications may change without notice.

1-1

IMPORTANT INFORMATION		GEN
		INFO

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1.Before removal and disassembly, remove all dirt, mud, dust and foreign material.

2.Use only the proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS”.

3.When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

4.During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

5.Keep all parts away from any source of fire.

EAS00021

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

1.When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2.During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.

1-2

IMPORTANT INFORMATION		GEN
		INFO

EAS00024

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

Oil seal

CAUTION

Do not spin the bearing with compressed air because this will damage the bearing surfaces.

Bearing

EAS00025

CIRCLIPS

Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip , make sure the sharp-edged corner is positioned opposite the thrust that the circlip receives.

Shaft

1-3

CHECKING THE CONNECTIONS		GEN
		INFO

EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc.

1.Disconnect:

•lead

•coupler

•connector

2.Check:

•lead

•coupler

•connector

Moisture Dry with an air blower. Rust/stains Connect and disconnect several times.

3.Check:

•all connections

Loose connection Connect properly.

NOTE:

If the pin on the terminal is flattened, bend it up.

4.Connect:

•lead

•coupler

•connector

NOTE:

Make sure all connections are tight.

5.Check:

•continuity

(with the pocket tester)

Pocket tester 90890-03112, YU-3112

NOTE:

•If there is no continuity, clean the terminals.

•When checking the wire harness, perform steps (1) to (3).

•As a quick remedy, use a contact revitalizer available at most part stores.

1-4

SPECIAL TOOLS		GEN
		INFO

EAS00027

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.	Tool name / Usage						Illustration
90890-01312	Fuel level gauge
	This gauge is used to measure the fuel level in
	the float chamber.
90890-03113	Engine tachometer
	This tool is needed for detecting engine rpm.
90890-04086	Universal tool of subjection of the clutch
	This tool is used to immobilize the clutch
	during the assembly or disassembly of the
	blockade nut of the clutch.
90890-01701	Sheave holder
	This tool is used for holding the secondary
	sheave.
90890-01362	Flywheel puller
	For removing the flywheel.
90890-01304	Piston pin puller
	This tool is used to remove the piston pin.
90890-01325	Radiator cap tester
90890-01352	Adaptor
	These tools are used for checking the
	cooling system.

1-5

	SPECIAL TOOLS				GEN
					INFO
Tool No.	Tool name / Usage				Illustration
90890-01135	Crankcase separation tool
	This tool is used to remove the crankshaft
	or separate the crankcase.
90890-01274 (1)	Cranckshaft intalling tool
-01275 (2)	Crankshaft pin
-01278 (3)	Adapter(M12)
90890-01326	T-Handle
	This tool is used for holding the damper
	rod holder when removing or installing
	the damper rod holder.
90890-01367	Fork seal driver weight
-01381	Fork seal driver attachment
	This tool is used when installing the fork seal.
90890-01403	Ring nut wrench
	This tool is used to loosen and tighten
	the steering ring nut.
90890-03112	Pocket tester
	These instruments are invaluable for
	checking the electrical system.

1-6

SPEC

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS …………………………………………………2-1 ENGINE SPECIFICATIONS……………………………………………………2-4 CHASSIS SPECIFICATIONS …………………………………………………2-6 ELECTRICAL SPECIFICATIONS ……………………………………………2-8

CONVERSION TABLE …………………………………………………………2-10

GENERAL TIGHTENING TORQUE SPECIFICATIONS ……………………2-10 ENGINE ………………………………………………………………………2-11 CHASSIS ……………………………………………………………………2-11

COOLANT FLOW CHART ……………………………………………………2-13

LUBRICATION POINTS AND LUBRICANT TYPE …………………………2-14 ENGINE ………………………………………………………………………2-14 CHASSIS ………………………………………………………………………2-15

CABLE ROUTING ………………………………………………………………2-16

GENERAL SPECIFICATIONS		SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS

Model	DT125RE		DT125X
Model code	1D01/1D02		2C81
Dimensions:
Overall lenght	2210mm		2139mm
Overall width	795mm		1121mm
Overall height	1200mm		1200mm
Seatheight	900mm		886mm
Wheelbase	1415mm		1396mm
Minimum ground clearance	300mm		271 mm
Minimum turning radius	2100mm		2016mm
Basic weight:
With oil and full fuel tank	126kg		134 kg
Engine:
Engine type:	2 strokes, liquid cooled
Induction system	Reed valve
Cylinder arrangement	Forward-inclined single cylinder
Displacement	124cm3
BorexStroke	56,0x50,7
Compression ratio	6,7:1
Maximum power	11kW /8000rpm
Maximum torque	13Nm/8000rpm
Idle speed	1250~1450r/min
Starting system	Electric starter
Lubrication system	Yamaha Autolube
Oil type or grade:
Engine oil	2T motor oil (JASO grade FC)
Total amount	1,3L
Transmission oil	Type SE motor oil
Periodic oil change	0,75L (0,79 us. qt.)
Total amount	0,8L (0,85 us.qt.)
Radiator capacity:
Total amount (including all routes)	0,92L
Coolant reservoir capacity	0,30L
Air filter:	Wet type element
Fuel
Type	Regular unleaded gasoline
Fuel tank capacity:	10,7L
Reserve	1,8L
Carburetor:
Type/quantity	TM28-92 / 1
Manufacturer:	MIKUNI

2-1

GENERAL SPECIFICATIONS		SPEC

Model code		1D01/1D02		2C81
Spark plug:
Type		BR8ES
Manufacturer		NGK
Spark plug gap		0,7~0,8mm (0,0276~0,03315in)
Clutch type		Wet, multiple disc
Transmission:
Primary reduction system		Helical gear
Primary reduction ratio		71/22(3,227)
Secondary reduction system		chain drive
Secondary reduction ratio		57/16(3,563)
Transmission type		Constant mesh, 6 speed
Operation		Left foot operation
Gear ratio:
1ª		34/12(2.833)
2ª		30/16(1.875)
3ª		24/17(1.412)
4ª		24/21(1.143)
5ª		22/23(0.957)
6ª		18/22(0.818)
Chassis:
Frame type:		Semi double cradle		Semi double cradle
Castor angle		27º		24,5°
Trail		107mm		73,1 mm
Tire:
Type		With tube		With tube
Size	Front	80/90-21 48P		120/70-17 58H
	Rear	110/80-18 58P		140/70-17 66H
Manufacturer		Michelin /T63		Pirelli/ Sport Demon
Cold tire pressure:		150kPa (1.5kgf/cm2)		180kPa (1.8kgf/cm2)
Front	0~90kg
Rear	0~90kg	175kPa (1.75kgf/cm2)		200kPa (2.0kgf/cm2)
Front	90~178kg	175kPa (1.75kgf/cm2)		180kPa (1.8kgf/cm2)
Rear	90~178kg	200kPa (2.0kgf/cm2)		200kPa (2.0kgf/cm2)
Off road riding:		150kPa (1.5kgf/cm2)
Front
Rear		175kPa(1.75kgf/cm2)
Brakes:
Front brake type		Single disc brake		Single disc brake
		230mm diameter		298 mm diameter
Front brake operation		Right hand operation		Right hand operation
Rear brake type		Single disc brake		Single disc brake
		220mm diameter		220 mm diameter
Rear brake operation		Right foot operation		Right foot operation
Suspensions:
Front		Telescopic fork
Rear		Swingarm (monocross suspension)
Shock absorber:
Front		Coil-air spring/Oil damper
Rear		Coil and gas spring/Oil damper

2-2

GENERAL SPECIFICATIONS		SPEC

Model code	1D01/1D02	2C81
Wheel travel:
Front wheel travel	270mm(10.63in)	200mm (7,87in)
Rear wheel travel	260mm(10.24in)	230mm (9.05in)
Electrical:
Ignition system	CDI
Charging system	AC Magneto
Battery type	GT6B-3
Capacity	12V 6Ah
Headlight:	bulb type
Bulb wattage x quantity:
Headlight	12V60W/55W x 1
Tail/Brake light	12V21W/5W x 1
Turn signal indicator light
Front	12V10W x 1
Rear	12V10W x 1
Meter	LED
Control lights:
“OIL”	12V3W X 1
“TURN”	12V3W X 1
“NEUTRAL”	12V3W X 1
“HIGH BEAM”	12V3W X 1
“LOW BEAM”	12V3W X 1
Amperages:
Principal fuse	15A

2-3

GENERAL SPECIFICATIONS		SPEC

ENGINE

Item							Standard	Limit
Cylinder head:
Warpage limit							* Lines indicate	0,03mm
							straightedge
							measurement.
Cylinder:
Bore size							56.00~56.02mm	***
Taper limit							0.05mm	***
Out of round limit							0.01mm	***
Piston:
Piston size “D”							55.950~55.955	***
Measurement point*							10mm	***
Piston to cylinder
clearance							0.045~0.050mm	0.10mm
Piston Offset							0.5mm	***
Piston ring:
Type							Keystone	***
Dimensions(BxT):							*	*
Top ring							1.2x2.4mm	***
2nd ring							1.20x1.89mm	***
End gap (installed):							*	*
Top ring							0.30~0.45mm	***
2nd ring							0.30~0.45mm	***
Side clearance:							*	*
Top ring							0.02~0.06mm	***
2nd ring							0.035~0.070mm	***
Cooling system:
Radiator capacity (including all routes)							0.92L	***
Reservoir tank capacity							0.3L	*
Radiator cap opening pressure							75~105kPa	***
							(0.75~1.05kgf/cm2)
Radiator core width							110mm	***
Radiator core height							280mm	***
Radiator core thickness							32mm	***
Water pump type							Single-suction centrifugal
							pump

2-4

GENERAL SPECIFICATIONS		SPEC

Item			Standard	Limit
Crankshaft:
Crank width “A”			57.90~57.95mm	***
Runout limit “C”			***	0.03mm
Big end side clearance	“D”		0.2~0.7mm	***
Small end free play “E”			0.026~0.040mm	***
Clutch:
Friction plate thickness			2.9~3.1mm	2.7mm
Quantity			7pcs	***
Clutch plate thickness			1.05~1.35mm	0.05mm
Quantity			6pcs	***
Clutch spring Free lenght			34.5mm	***
Quantity			5pcs	***
Minimum free lenght			32mm	***
Push rod bending limit			0.15mm	***
Transmission:
Main axle runout limit			***	0.08mm
Drive axle runout limit			***	0.08mm
Carburetor:
Type			TM28-92/1	***
ID Mark			1DO	***
Main jet			#210	***
Air jet			0.7	***
Jet Needle position			5J40-2	***
Needle jet			Q2M (#939)	***
Pilot outlet			0.6	***
Pilot jet			#17.5	***
Bypass1			1.6	***
Air screw turns			1/4	***
Valve seat size			2.8	***
Starter jet 1			#40	***
Power jet			#60	***
Float height			15.5~16.5mm	***
Fuel level			1.5~2.5mm
Idling speed			1250~1450r.p.m
Air filter:
Type			Wet element	***
Oil type/grade			Foam air filter oil or	***
			SAE10W30SE
Reed valve:
Valve thickness			0.5mm	***
Valve stopper height			8.8mm	***
Valve bending limit			0.5mm	***
Lubrication system:
Autolube pump			*	*
Color code			Dark blue	***
Minimum stroke			0.15~0.20mm	***
Maximum stroke			1.85~2.05mm	***
Minimum output			0.38~0.50cm3	***
Maximum output			4.65~5.15cm3	***
Pulley adjusting mark			autoadjustable	***

2-5

GENERAL SPECIFICATIONS		SPEC
CHASSIS

Item	Standard		Limit
Model code	1D0	2C81	1D0	2C81
Front wheel:
Type	Spoke wheels	Spoke wheels
Rim Size	21x1.60	17 x 3.00
Rim Material	Steel	Steel
Front wheel travel:	270mm	270mm
Max. Radial wheel runout	1mm	1mm
Max. Lateral wheel runout	0.5mm	0.5mm
Rear wheel:
Type	Spoke wheels	Spoke wheels
Rim size	18x1.85	17x3.50
Rim material	Steel	Steel
Rear wheel travel	260mm(10.24in)	260mm(10.24in)
Max. Radial wheel runout	1mm(0.04in)	1mm(0.04in)
Max. Lateral wheel runout	0.5mm(0.02in)	0.5mm(0.02in)
Front disc brake:
Thickness	230.0x3.5mm	230.0x3.5mm
Brake pad lining thickness-inner	6mm	4.1mm	0.8mm	0.5mm
Brake pad lining thickness-outer	6 mm	6 mm	0.8mm	0.8mm
Master cylinder inside diameter	11mm	11mm
Caliper cylinder inside diameter	34.93mm	34.93mm
Recommended fluid	DOT 4	DOT 4
Rear disc brake:
Thickness	220.0x4.5mm
Brake pad lining thickness-inner	5.6mm		1.0mm
Brake pad lining thickness-outer	5.6mm		1.0mm
Master cylinder inside diameter	12.7mm
Caliper cylinder inside diameter	30.16mm
Recommended fluid	DOT 4
Steering system:
Steering type	Ball and taper roller
Bearing size (quantity)	bearing
Upper	22pcs (0.1875in)
Front suspension:
Front fork travel	270mm	200 mm
Fork free lenght	503mm	503mm
Spring rate K1	3.1N/mm	3.1N/mm
Spring stroke K1	0~270mm	0~270mm
Optional spring available	No	No
Recommended oil	Fork oil 10W	Fork oil 10W
Quantity	495cm3	495cm3
Level	165.5mm	165.5mm

2-6

GENERAL SPECIFICATIONS		SPEC

Item	Standard		Limit
Model code	1D0	2C81	1D0	2C81
Rear suspension:
Type	Swingarm	Swingarm
	(link suspension)	(link suspension)
Rear shock absorber assemby travel	93mm	87 mm
Spring free lenght	245mm	250mm
Installed lenght	230mm	244mm
Spring preload (spring lenght)	Hard/Soft	Hard/Soft
	(220/235mm)	(234/249mm)
Spring rate K1	68.6N/mm	117.80N/mm
Spring stroke K1	0~93mm	0~87mm
Optional spring available	No	No
Enclosed gas/air pressure (STD)	150kPa	150kPa
	(15kgf/cm2)	(15kgf/cm2)
Tightening torque spring preload	20~25Nm	20~25Nm
Drive chain:
Type/Manufacturer	428V2/DAIDO	428V2/DAIDO
Link quantity	134	134
Drive chain slack	45~55mm	25~40mm
	(1.77~2.16in)	(0.98~1.57in)
Front lever brake/Rear brake pedal:
Free play front lever brake	2~5mm
Brake pedal free play	15mm

2-7

	GENERAL SPECIFICATIONS					GEN
						INFO
ELECTRICAL
Model		1D01/1D02				2C81
System voltage		12 V
Ignition system:
Ignition system type		C.D.I.
Ignition timing (B.T.D.C.) ((º))		17 /1500r/min
Advancer type		Digital
C.D.I.:
Magneto model/manufacturer		F4FU/YAMAHA
Pick up coil resistance((ohm))		310±20%W/R-W/L
Source coil resistance ((ohm))		730±20%B/R-G/W
Source coil resistance ((ohm))		600±20%G/L-G/W
CDI unit model/manufacturer		1D0 /YAMAHA
Ignition coil:
Model/Manufacturer		3RW/YAMAHA
Primary coil resistance ((ohm))		0.23±20%
Secondary coil resistance ((ohm))		7.9±20%
Spark plug cap:
Material		Resin
Resistance ((k ohm))		5
A.C. Magneto:
Model/Manufacturer		F4FU/YAMAHA
Standard output		14V170W5000r/min
Coil resistance ((ohm))		0.6±20%W-W
Regulator:
Regulator type		Semi conductor-short circuit
Model/Manufacturer		SH629B-11/SHINDENGEN
No load regulated voltage		14.1~14.9V
Rectifier:
Rectifier capacity		25A
Withstand voltage		200V
Battery:
Battery type		GT6B-3
Battery voltage/Capacity		12V6Ah
Bulbs (voltage/wattage x quantity)
Headlight type		Bulb type
Headlight bulb type		Halogen H4
Headlight		12V60W/55Wx1
Auxiliary light		12V5Wx1
Brake/tail light		12V21W/5Wx1
Front flasher light		12V10Wx2
Rear flasher light		12V10Wx2
Meter light		LED

2-8

	GENERAL SPECIFICATIONS				GEN
					INFO
Indicator light
Neutral indicator light		12V3Wx1
Turn indicator light		12V3Wx1
Oil level indicator light		12V3Wx1
High beam indicator light		12V3Wx1
Starting system:
System type		Electric starter
Starter motor:
Model/Manufacturer		3MB / Moric
Power output		0.2kW
Armature coil resistance		0.0315~0.0385<ohm> 20ºC
Brush overal lenght		5X7X7
<Limit>		3,5
Brush spring force		4.9N ±20%
<Limit>		3.92N
Commutator diameter		17.6mm
<Limit>		16.6mm
Mica undercut (depth)		1.35mm
Starter relay:
Model/Manufacturer		1D0/JIDECO
Amperage		180A
Coil resistance		4.2 - 4.6<ohm> 20ºC
Horn:
Horn type		Plane
Quantity		1
Model/Manufacturer		YF-12/NIKKO
Max. Amperage		3A
Performance		105~113db/2m
Turn signal relay:
Relay type		Full transistor
Model/Manufacturer		FE218BH/DENSO
Turn signal blinking frequency		75~95cyl/min
Wattage		10Wx2+3.4W
Oil level gauge:
Model/Manufacturer		3XP/ASTI
Starting citcuit cutt-off relay:
Model/Manufacturer		25G/OMRON
Coil resistance		100<ohm>±10%
Headlight relay:
Model/Manufacturer		25G/OMRON
Coil resistance		100<ohm>±10%
Side stand relay:		BUILT IN CUT OFF RELAY
Thermostat switch:
Model/Manufacturer		4BA/DENSO
Temperature setting		120±3<degree>
Servo motor:
Model/Manufacturer		3XP/MATSUSHITA
Amperage for fuses:
Main fuse		15A
Spare fuse		15A

2-9

CONVERSION TABLE /		SPEC
GENERAL TIGHTENING TORQUES SPECIFICATIONS

EAS00028 EAS00029

CONVERSION TABLE

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			MULTIPLIER			IMPERIAL
** mm		x	0.03937		=	** in
2 mm		x	0.03937		=	0.08 in
		CONVERSION TABLE
	METRIC TO IMPERIAL
	Metric unit			Multiplier		Imperial unit
		m•kg		7.233		ft•lb
Tightening		m•kg		86.794		in•lb
Torque		cm•kg		0.0723		ft•lb
		cm•kg		0.8679		in•lb
Weight		kg		2.205		lb
			g	0.03527		oz
Speed		km/hr		0.6214		mph
		km		0.6214		mi
		m		3.281		ft
Distance		m		1.094		yd
		cm		0.3937		in
		mm		0.03937		in
		cc (cm3)		0.03527		oz (IMP liq.)
Volume,		cc (cm3)		0.06102		cu•in
Capacity		lt (liter)		0.8799		qt (IMP liq.)
		lt (liter)		0.2199		gal (IMP liq.)
		kg/mm		55.997		lb/in
Misc.		kg/cm2		14.2234		psi (lb/in2)
	Centigrade			9/5 + 32		Fahrenheit (°F)
		(°C)

GENERAL TIGHTENING TORQUE SPECIFICATIONS

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.

A:Width across flats

B:Thread diameter

	A	B	General tightening
			torques
	(nut)	(bolt)
			Nm	m • kg
	10 mm	6 mm	6	0.6
	12 mm	8 mm	15	1.5
	14 mm	10 mm	30	3.0
	17 mm	12 mm	55	5.5
	19 mm	14 mm	85	8.5
	22 mm	16 mm	130	13.0

2-10

DEFINITION OF UNITS		SPEC

TIGHTENING TORQUES

ENGINE

				Tightening
			Thread	torque
Part to be tightened		Q’ty	size	Nm	m•kg	Remarks
Spark plug		1	M14x1.25	20	2,0
Cylinder head	Nut	5	M8x1.25	22	2,2
Cylinder	Stud bolt	9	M8X1.25	13	1,3	LOCTITE
						screw glue
	Nut	4	M8x1.25	28	2,8
Power valve holder, Valve cover	Cap seal
	Bolt	6	M5x0.8	7	0,7
Power valve pully	Bolt		M6x1.0	10	1,0
Thermostat valve cover	Screw	3	M6x1.0	8	0,8
Housing cover	Screw	2	M6x1.0	8	0,8
	Drain bolt (Housing cover)	1	M6x1.0	10	1
Radiator	Bolt	2	M6x1.0	8	0,8
Radiator cap stopper	Screw	1	M5x0.8	5	0,5
Oil pump	Screw	2	M5x0.8	5	0,5
Carburetor joint	Bolt	4	M6x1.0	8	0,8
Air filter	Screw	2	M6x1.0	5	0,5
Exhaust pipe	Nut	2	M8x1.25	18	1,8
	Stud bolt	2	M8x1.25	10	1	LOCTITE
						screw glue
	Bolt	3	M6x1.0	8	0,8
Transmission Oil	Drain Bolt	1	M8x1.25	15	1,5
Crankcase cover (left)	Screw	6	M6x1.0	5	0,5
Crankcase cover (right)	Screw	6	M6x1.0	8	0,8
Oil pump cover	Screw	3	M6x1.0	5	0,5
Crankcase	Screw	12	M6x1.0	8	0,8
Oil Seal Holder	Screw	1	M8x1.25	16	1,6
Cover	Screw	2	M6x1.0	8	0,8
Kick Crank Bass	Nut	1	M12X1.0	70	7
Clutch Spring	Bolt	5	M5x0.8	6	0,6
Plate cover	Screw	2	M6x1.0	10	1
Drive Sprocket	Nut	1	M16X1.0	60	6
Tachometer housing	Bolt	1	M6x1.0	5	0,5
Stopper lever	Bolt	1	M6x1.0	14	1,4	LOCTITE
						screw glue
Shift pedal	Bolt	1	M6x1.0	15	1,5
Thermo unit
Rotor		1	~	15	1,5
	Nut	1	M12x1.25	80	8

2-11

DEFINITION OF UNITS		SPEC
CHASSIS

		Tightened
	Thread	torque
Parts to be tightened	size	Nm	m•kg	Remarks
Engine stay (Top) and frame	M10	30-35	3,0-3,5
Cylinder head stay (Top) and frame	M10	30-35	3,0-3,5
Bottom screw (front) engine and frame	M10	60-78	6,0-7,8
Bottom screw (front) engine to swingarm	M10	30-35	3,0-3,5
Steering nut	M25	120-155	12,0-15,5	Steering must turn
				smoothly and
				without free play
Fuel cock lever	M6	5~8	0,5~0,8
Upper bracket and meter holder	M6	5~8	0,5~0,8
Rear bolt fuel tank to frame	M6	7,5-12	0,75-1,2
Footrest security pins	—	Completely bend
Front brake holder	M10	2~3	0,2~0,3
Front brake pipe	M10	23-37	2,3-3,7
Handlebar holder bolts to handlebars	M8	5~8	0,5~0,8
Main switch	M6	7~12	0,7~1,2	Security allen bolt
				(with central pin)
Top holder bolts to suspension tubes	M8	12~28	1,2~2,8
Sidestand nut	M8	20-32	2,0-3,2
Rear brake lever	M8	7,5-12	0,75-1,2
Rear master cylinder to holder	M6	7,5-12	0,75-1,2
Brake pipe bolt	M10	23-37	2,3-3,7
Security pin rear brake lever to pump	—	Completely bend
Pivot shaft	M15	80-100	8,0-10,0
Swingarm to connecting arm	M13	45-70	4,5-7,0
Connecting arm relay arm	M13	45-70	4,5-7,0
Relay arm to frame	M13	45-70	4,5-7,0
Damper to frame	M10	30-35	3,0-3,5
Damper to relay arm	M10	30-35	3,0-3,5
Swingarm end bolts	—	2~4	0,2-0,4
Driven sprocket	M8	32-37	3,2-3,7
Rear wheel axle nut	M17	80-100	8,0-10,0	Check that the pin is
				bent
Front brake caliper to outer tube	M10	31-49	3,1-4,9
Front wheel axle	M15	45-70	4,5-7,0
Exhaust to cylinder head	M8	15-20	1,5-2,0
Exhaust assy 1 to central exhaust pipe	M8	8~12	0,8-1,2
Central exhaust pipe to muffler	M8	8~12	0,8-1,2
Muffler and central pipe to frame holder	M8	38-42	3,8-4,2
Clutch lever pivot nut	M6	5~8	0,5-0,8
Front brake pivot lever nut	M6	5~8	0,5-0,8
Front brake lever adjusting nut	M6	5~8	0,5-0,8
Security nuts	M6	7,5-12	0,75-1,2
Chain puller	M6	18-28	1,8-2,8
shift shaft nut	M6	8~12	0,8-1,2
Rear footrest holder	M8	17-22	1,7-2,2
Bottom bolts inner holder to tube	M8	20-25	2,0-2,5

2-12

COOLANT FLOW CHART		SPEC

COOLANT FLOW CHART

Water pump Crankcase cover Crankcase Cylinder

Cylinder head

Bypass hose	Thermostatic valve

(Thermostatic valve)

Outlet hose			Radiator			Inlet hose

Coolant cold (Less than 65°C (149°F))

Coolant hot (165°(149°F) or more)

2-13

LUBRICATION POINTS AND LUBRICANT TYPES		SPEC

EAS00031

ENGINE

Lubrication points (part name)

Lubricant Type

Oil seal lips (All)

Apply lightweight lithium-soap base grease

O-Rings (All)

Apply lightweight lithium-soap base grease

Bearing retainer

Crankshaft bearings (Left and center)

Apply engine oil

Needle bearings (Connecting rod)

Apply engine oil

Main axle bearings

Apply gear oil

Drive axle bearings

Apply gear oil

Push lever bearings

Apply gear oil

Crank pins

Apply engine oil

Piston rings - piston pins and pistons

Apply engine oil

Power valve holder

Apply lightweight lithium-soap base grease

Impeller shaft (water pump)

Apply gear oil

Warm shaft (Autolube pump)

Apply engine oil

Kick idle gear

Apply gear oil

Kick axle

Apply gear oil

Primary driven gear (clutch housing)

Apply gear oil

Push rod

Apply gear oil

Push lever axle

Apply gear oil

Sliding gear (Transmission)

Apply molybdenum disulfide grease

Free movement gear (Transmission)

Apply molybdenum disulfide grease

Guide bar (Shift forks)

Apply gear oil

Crankcase mating surfaces

Yamaha bond no.4

2-14

LUBRICATION POINTS AND LUBRICANT TYPES		SPEC

EAS00032

CHASSIS

Lubrication points (part name)	Lubricant Type
Ball bearing (Steering shaft)	Apply lightweight lithium-soap base grease
Bearing (Steering shafts)	Apply lightweight lithium-soap base grease
Oil seal clutch to lever	Apply lightweight lithium-soap base grease
Clutch lever axle free play	Apply lightweight lithium-soap base grease
Throttle guide bar	Apply lightweight lithium-soap base grease
Oil seal throttle wire to guide	Apply lightweight lithium-soap base grease
Front brake lever axle free play	Apply lightweight lithium-soap base grease
Footrests free play	Apply lightweight lithium-soap base grease
Rear footrests free play (ball and axle)	Apply lightweight lithium-soap base grease
Swingarm axle to frame	Apply lightweight lithium-soap base grease
Relay arm to swingarm	Apply lightweight lithium-soap base grease
Connecting rods	Apply lightweight lithium-soap base grease
Engine holder to cylinder head	Apply lightweight lithium-soap base grease
Rear brake lever pivot	Apply lightweight lithium-soap base grease
Sidestand pivot	Apply lightweight lithium-soap base grease
Oil seal lip (front wheel)	Apply lightweight lithium-soap base grease
Front wheel axle outer surface	Apply lightweight lithium-soap base grease
Oil seal lip (rear wheel)	Apply lightweight lithium-soap base grease
Rear wheel axle outer surface	Apply lightweight lithium-soap base grease

2-15