Yamaha FZS1000N, FZS1000NC Service Manual

EAS00001

or unauthorized use without the written

permission of Yamaha Motor Corporation,

FZS1000N (C)

SERVICE MANUAL

2001 by Yamaha Motor

Corporation, U.S.A.

First edition, January 2001

All rights reserved. Any reproduction

U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N LIT-11616-14-48

EAS00003

NOTICE

This manual was produced by the Y amaha Motor Company , Ltd. primarily for use by Y amaha 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.

This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools in necessary to ensure that the ve­hicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Y amaha dealer for any service information changes that apply to this model. This policy
is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed­eral environmental quality objectives.

Y amaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi­cant changes in specifications or procedures will be forwarded to all authorized Y amaha dealers and
will appear in future editions of this manual where applicable.

NOTE:

S This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

S Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATION

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death
the motorcycle operator, a bystander or a person checking or repairing the mo­torcycle.

CAUTION:

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

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

to

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.

1

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” on the following page.

2

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 sub-section title(-s) appears.
(In Chapter 3, “Periodic Checks and Adjustments”, the sub-section title appears at the top of each

page, instead of the section title.)

3

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

4

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

removal and disassembly section.

5

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

disassembly step.

6

Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

7

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8

Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

6

4

5

7

1

2

3

8

1

GEN

INFO

3

CHK

ADJ

5

COOL

7

2

SPEC

4

ENG

6

CARB

8

ELECCHAS

EAS00008

SYMBOLS

The following symbols are not relevant to every
vehicle.
Symbols
chapter.

General information

1

Specifications

2

Periodic checks and adjustments

3

Engine

4

Cooling system

5

Carburetor(-s)

6

Chassis

7

Electrical system

8

Troubleshooting

9

1

to 9 indicate the subject of each

9

10

TRBL

SHTG

11 12

1413

16 1715

19 2018

22

24 25

Symbols10 to 17 indicate the following.

10

Serviceable with engine mounted

11

Filling fluid

12

Lubricant

13

Special tool

14

Tightening torque

15

Wear limit, clearance

16

Engine speed

17

Electrical data

Symbols18 to 23 in the exploded diagrams indi­cate the types of lubricants and lubrication
points.

18

Engine oil

19

Gear oil

2321

20

Molybdenum disulfide oil

21

Wheel bearing grease

22

Lithium soap base grease

23

Molybdenum disulfide grease

Symbols24 to 25 in the exploded diagrams indi­cate the following:

24

Apply locking agent (LOCTITER)

25

Replace the part

EAS00012

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND
ADJUSTMENTS

ENGINE

COOLING SYSTEM

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

1
2
3
4
5

CARBURETORS

CHASSIS

ELECTRICAL SYSTEM

TROUBLESHOOTING

CARB

CHAS

ELEC

TRBL
SHTG

6
7
8
9

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .

MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2. . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN

INFO

MOTORCYCLE IDENTIFICATION

EAS00014

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number
into the right side of the steering head.

EAS00018

MODEL CODE

The model code label
This information will be needed to order spare
parts.

GEN

INFO

1

is stamped

1

is affixed to the frame.

1-1

IMPORTANT INFORMATION

EAS00020

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” section.

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.

GEN

INFO

lip

oil

lip

spring

grease

EAS00021

REPLACEMENT PARTS

1. 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 apply grease onto
the oil seal lips with greace.

EAS00023

LOCK WASHERS/PLATES AND COTTER
PINS

1. After removal, replace all lock wash­ers/plates

1

and cotter pins. After the bolt or
nut has been tightened to specification, bend
the lock tabs along a flat of the bolt or nut.

1-2

IMPORTANT INFORMATION

EAS00024

BEARINGS AND OIL SEALS

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

Oil seal

1

CAUTION:

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

Bearing

1

GEN

INFO

EAS00025

CIRCLIPS

1. Before reassembly , check all circlips careful­ly and replace damaged or distorted circlips.
Always replace piston pin clips after one use.

1

When installing a circlip
the sharp-edged corner
posite the thrust

Shaft

4

3

that the circlip receives.

, make sure that

2

is positioned op-

1-3

CHECKING THE CONNECTIONS

EAS00026

CHECKING THE CONNECTIONS

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

1. Disconnect:

S lead
S coupler
S connector

2. Check:

S lead
S coupler
S connector

3. Check:

S all connections

NOTE:

If the pin
up.

1

2

3

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

Loose connection ! Connect properly.

1

on the terminal is flattened, bend it

GEN

INFO

4. Connect:

S lead
S coupler
S connector

NOTE:

Make sure that all connections are tight.

5. Check:

S continuity

(with a pocket tester)

Pocket tester measurement

YU-03112-C

NOTE:

S If there is no continuity, clean the terminals.
S When checking the wire harness, perform

steps 1 to 3.

S As a quick remedy, use a contact revitalizer

available at most part stores.

1-4

GEN

SPECIAL TOOLS

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.

INFO

Tool No.

YM-01080-A

YU-01235

YU-01304

YU-01312-A

Radiator
Pressure Tester
YU-24460-01
Radiator
Pressure
Tester Adapter
YU-33984

Tool name/Function Illustration

Alternator Rotor Puller

This tool is used to remove the generator
rotor.

Universal Magneto & Rotor Holder

This tool is used to hold the generator rotor
when removing or installing the generator
rotor bolt or pickup coil rotor bolt.

Piston Pin Puller

This tool is used to remove the piston pins.
Fuel Level Gauge

This tool is used to measure the fuel level in
the float chamber.

Radiator Pressure Tester
Radiator Pressure Tester Adapter

These tools are used to check the cooling
system.

Spanner Wrench

YU-33975

This tool is used to loosen or tighten the
steering stem ring nuts.

Steering Nut Wrench

YU-1268

This tool is used to loosen the steering stem
ring nuts.

Damper Rod Holder

YM-01447

This tool is used to hold the damper rod
assembly when loosening or tightening the
damper rod assembly bolt.

1-5

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Oil Filter Wrench

YU-38411

This tool is needed to loosen or tighten the
oil filter cartridge.

Rod Holder

YM-01434

This tool is used to support the damper
adjusting rod.

Rod Puller

Rod puller
YM-01437

This tool is used to pull up the front fork
damper rod.

GEN

INFO

Driver
YM-33963
43 mm
Adapters
YM-8020-A

YU-03008

YU-8030

Compression
Gauge Set
YU-33223

Driver
43 mm Adapters

This tool is used to install the front fork’s oil
seal and dust seal.

Micrometers (50 X 75 mm)

This tool is used to measure the piston skirt
diameter.

Carburetor Synchronizer

This guide is used to synchronize the
carburetors.

Compression Gauge Set

Compression Gauge Adapter

These tools are used to measure engine
compression.

Pocket Tester Measurement

YU-03112-C

This tool is used to check the electrical
system.

Inductive Self-Powered Tachometer

YU-8036-B

This tool is used to check engine speed.

1-6

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Battery Powered Timing Light

YM-33277-A

This tool is used to check the ignition
timing.

Valve Spring
Compressor
YM-04019
Adapter
YM-4108
YM-4114

40 and 50 mm
Bearing Driver
YM-4058
Water Pump
Seat Installer
YM-33221

Valve Spring Compressor Set, Quick
Release
Adapter

These tools are used to remove or install
the valve assemblies.

40 and 50 mm Bearing Driver
Water Pump Seal Installer

These tools are used to install the water
pump seal.

Universal Clutch Holder (Grabbit)

GEN

INFO

YM-91042

YM-04111
YM-4116

YM-04112
YM-4117

YM-04113
YM-4118

This tool is used to hold the clutch boss
when removing or installing the clutch boss
nut.

Valve Guide Remover (ø4)
Valve Guide Remover (ø4.5)

This tool is used to remove or install the
valve guides.

Valve Guide Installer (ø4)
Valve Guide Installer (ø4.5)

This tool is used to install the valve guides.
Valve Guide Reamer (ø4)

Valve Guide Reamer (ø4.5)

This tool is used to rebore the new valve
guides.

Dynamic Spark Tester

YM-34487

This tool is used to check the ignition
system components.

Yamaha bond No. 1215

ACC-11001­05-01

This bond is used to seal two mating
surfaces (e.g., crankcase mating surfaces).

1-7

SPEC

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUES 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TIGHTENING TORQUES 2-18. . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE TIGHTENING TORQUES 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS TIGHTENING TORQUES 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 2-23. . . . . . . . . . . . . . . .

ENGINE 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM DIAGRAMS 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL LUBRICATION CHART 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPEC

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 5LV5 (USA except for California)

5LV6 (CDN)
5LV7 (California)

Dimensions

Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius

Weight

Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,

passenger, and accessories)

2,125 mm (83.7 in)
765 mm (30.1 in)
1,190 mm (46.9 in)
820 mm (32.3 in)
1,450 mm (57.1 in)
140 mm (5.5 in)
2,900 mm (114.2 in)

231 kg (509 lb)
232 kg (512 lb) (for california)
208 kg (459 lb)
209 kg (461 lb) (for california)
189 kg (417 lb)
188 kg (415 lb) (for california)

SPEC

2-1

ENGINE SPECIFICATIONS

Item Standard Limit

Engine

Engine type
Displacement
Cylinder arrangement
Bore X stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)

Fuel

Recommended fuel
Fuel tank capacity

Total (including reserve)
Reserve only

Engine oil

Lubrication system
Recommended oil

ENGINE SPECIFICATIONS

SPEC

Liquid-cooled, 4-stroke, DOHC
998 cm

3

Forward-inclined parallel 4-cylinder
74 X 58 mm (2.91 X 2.28 in)

11.4 : 1
1,050 X 1,150 r/min
30 kPa (225 mmHg, 8.86 in Hg)

1,450 kPa

2

(14.5 kg/cm

, 206 psi) at 400 r/min

Unleaded fuel (for USA)
Regular unleaded gasoline (for CDN)

21 L (18.5 Imp qt, 22.2 US qt)

4.0 L (3.52 Imp qt, 4.22 US qt)

Wet sump
Yamalube 4 (20W40) or SAE 20W40 type

SE motor oil

Quantity

Total amount
Without oil filter cartridge
replacement
With oil filter cartridge
replacement

Oil pressure (hot)
Relief valve opening pressure

3.7 L (3.2 Imp qt, 3.8 US qt)

2.8 L (2.4 Imp qt, 2.9 US qt)

3.0 L (2.6 Imp qt, 3.1 US qt)

2

45 kPa (0.45 kg/cm

, 6.40 psi) at
1,100 r/min
490 X 570 kPa

2

(4.9 X 5.7 kg/cm

, 69.7 X 81.1 psi)

2-2

ENGINE SPECIFICATIONS

Item Standard Limit

Oil filter

Oil filter type
Bypass valve opening pressure

Oil pump

Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance

Cooling system

Radiator capacity
Radiator cap opening pressure

Radiator core

Width
Height
Depth

Coolant reservoir

Capacity

Water pump

Water pump type
Reduction ratio
Max. impeller shaft tilt

Starting system type Electric starter

Cartridge (paper)
180 X 220 kPa
(1.8 X 2.2 kg/cm

Trochoidal

0.09 X 0.15 mm (0.004 X 0.006 in)

0.03 X 0.08 mm (0.001 X 0.003 in)

2.4 L (2.11 Imp qt, 2.53 US qt)
95 X 125 kPa
(0.95 X 1.25 kg/cm

340 mm (13.4 in)
238 mm (9.4 in)
24 mm (0.94 in)

0.3 L (0.26 Imp qt, 0.32 US qt)
Single-suction centrifugal pump

68/43 X 28/28 (1.581)

2

, 25.6 X 31.3 psi)

2

, 13.1 X 17.8 psi)

SPEC

0.15 mm
(0.006 in)

Spark plugs

Model (manufacturer) X quantity
Spark plug gap

Cylinder head

Max. warpage

CR9E/U27ESR-N (NGK/DENSO) X 4

0.7 X 0.8 mm (0.028 X 0.031 in)

0.1 mm
(0.004 in)

2-3

Item Standard Limit

Camshafts

Drive system
Camshaft cap inside diameter

Camshaft journal diameter
Camshaft-journal-to-camshaft-

cap clearance
Intake camshaft lobe dimensions

ENGINE SPECIFICATIONS

Chain drive (right)

24.500 X 24.521 mm
(0.9646 X 0.9654 in)

24.459 X 24.472 mm
(0.9630 X 0.9635 in)

0.028 X 0.062 mm (0.0011 X 0.0024 in)

SPEC

Measurement A
Measurement B

Measurement C
Exhaust camshaft lobe
dimensions

Measurement A

Measurement B

Measurement C
Max. camshaft runout

32.5 X 32.6 mm (1.2795 X 1.2835 in)

24.95 X 25.05 mm (0.9823 X 0.9862 in)

7.45 X 7.65 mm (0.2933 X 0.3012 in)

32.95 X 33.05 mm (1.2972 X 1.3012 in)

24.95 X 25.05 mm (0.9823 X 0.9862 in)

7.75 X 7.95 mm (0.3051 X 0.3126 in)

32.4 mm
(1.2756 in)

24.85 mm
(0.9783 in)

32.85 mm
(1.2933 in)

24.85 mm
(0.9783 in)

0.03 mm
(0.0012 in)

2-4

ENGINE SPECIFICATIONS

Intake

0.21 X 0.25 mm (0.0083 X 0.0098 in)

Item Standard Limit

Timing chain

Model/number of links
Tensioning system

Valves, valve seats, valve guides

Valve clearance (cold)

Exhaust
Valve dimensions

Head Diameter Face Width Seat Width Margin Thickness

Valve head diameter A

Intake
Exhaust

Valve face width B

Intake
Exhaust

Valve seat width C

Intake
Exhaust

Valve margin thickness D

Intake
Exhaust

Valve stem diameter

Intake
Exhaust

Valve guide inside diameter

Intake
Exhaust

Valve-stem-to-valve-guide

clearance

Intake
Exhaust

RH2015/130
Automatic

0.11 X 0.20 mm (0.0043 X 0.0079 in)

X

22.9 X 23.1 mm (0.9016 X 0.9094 in)

24.4 X 24.6 mm (0.9606 X 0.9685 in)

1.76 X 2.90 mm (0.0693 X 0.1142 in)

1.76 X 2.90 mm (0.0693 X 0.1142 in)

0.9 X 1.1 mm (0.035 X 0.043 in)

0.9 X 1.1 mm (0.035 X 0.043 in)

0.5 X 0.9 mm (0.020 X 0.035 in)

0.5 X 0.9 mm (0.020 X 0.035 in)

3.975 X 3.900 mm (0.1565 X 0.1535 in)

4.465 X 4.480 mm (0.1758 X 0.1764 in)

4.000 X 4.012 mm (0.1575 X 0.1580 in)

4.500 X 4.512 mm (0.1772 X 0.1776 in)

0.010 X 0.037 mm (0.0004 X 0.0015 in)

0.020 X 0.047 mm (0.0008 X 0.0019 in)

X

SPEC

3.945 mm
(0.1553 in)

4.43 mm
(0.1744 in)

4.05 mm
(0.1594 in)

4.55 mm
(0.1791 in)

0.08 mm
(0.0031 in)

0.10 mm
(0.0039 in)

2-5

ENGINE SPECIFICATIONS

Item Standard Limit

SPEC

Valve stem runout

Valve seat width

Intake
Exhaust

Valve springs

Free length

Intake
Exhaust

Installed length (valve closed)

Intake

Exhaust
Compressed spring force
(installed)

Intake

Exhaust
Spring tilt

SSS

0.9 X 1.1 mm (0.035 X 0.043 in)

0.9 X 1.1 mm (0.035 X 0.043 in)

38.90 mm (1.53 in)

40.67 mm (1.60 in)

34.50 mm (1.36 in)

35.00 mm (1.38 in)

82 X 96 N (8.2 X 9.6 kg, 18.4 X 25.4 lb)
110 X 126 N
(11.0 X 12.6 kg, 24.7 X 28.3 lb)

0.01 mm
(0.0004 in)

SSS
SSS

SSS
SSS

SSS
SSS

SSS
SSS

Intake

Exhaust

Winding direction (top view)

Intake

Exhaust

SSS

SSS

Clockwise
Clockwise

2-6

2.5_ /1.7 mm
(2.5_ /0.067 in)

2.5_ /1.8 mm
(2.5_ /0.071 in)

SSS
SSS

Item Standard Limit

Cylinders

Cylinder arrangement
Bore X stroke
Compression ratio
Bore
Max. taper

Max. out-of-round

Pistons

Piston-to-cylinder clearance
Diameter D

ENGINE SPECIFICATIONS

Forward-inclined, parallel 4-cylinder
74 X 58 mm (2.91 X 2.28 in)

11.4 : 1

74.00 X 74.01 mm (2.9134 X 2.9138 in)

0.030 X 0.055 mm (0.001 X 0.002 in)

73.955 X 73.970 mm
(2.9118 X 2.9122 in)

SPEC

0.05 mm
(0.0016 in)

0.05 mm
(0.0016 in)

0.12 mm
(0.005 in)

Height H
Piston pin bore (in the piston)

Diameter
Offset

Offset direction

Piston pins

Outside diameter
Piston-pin-to-piston-pin-bore

clearance

Piston rings

Top ring

Ring type
Dimensions (B X T)
End gap (installed)
Ring side clearance

5 mm (0.20 in)

17.002 X 17.013 mm
(0.6694 X 0.6698 in)

0.5 mm (0.0197 in)
Intake side

16.991 X 17.000 mm
(0.6689 X 0.6693 in)

0.002 X 0.022 mm
(0.00008 X 0.00087 in)

Barrel

0.90 X 2.75 mm (0.035 X 0.108 in)

0.32 X 0.44 mm (0.010 X 0.020 in)

0.030 X 0.065 mm (0.0012 X 0.0026 in)

17.043 mm
(0.6710 in)

16.971 mm
(0.6681 in)

0.072 mm
(0.0028 in)

2-7

2nd ring

ENGINE SPECIFICATIONS

Item Standard Limit

SPEC

Ring type
Dimensions (B X T)
End gap (installed)
Ring side clearance

Oil ring

Dimensions (B X T)
End gap (installed)

Connecting rods

Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code

Crankshaft

Taper

0.8 X 2.8 mm (0.031 X 0.110 in)

0.43 X 0.58 mm (0.017 X 0.023 in)

0.020 X 0.055 mm (0.0008 X 0.0022 in)

1.5 X 2.6 mm (0.059 X 0.101 in)

0.10 X 0.35 mm (0.004 X 0.014 in)

0.031 X 0.055 mm (0.0012 X 0.0022 in)
–1 = Violet 0 = White 1 = Blue

2 = Black

Width A
Width B
Max. runout C

Big end side clearance D
Crankshaft-journal-to-crankshaft­journal-bearing clearance
Bearing color code

Clutch

Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end of the
clutch lever)

52.40 X 57.25 mm (2.063 X 2.254 in)

300.75 X 302.65 mm (11.84 X 11.92 in)

0.03 mm
(0.0012 in)

0.160 X 0.262 mm (0.006 X 0.010 in)

0.029 X 0.053 mm (0.0011 X 0.0021 in)
–1 = Pink/violet 0 = Pink/white

1 = Pink/blue 2 = Pink/black
3 = Pink/brown

Wet, multiple disc
Cam (pull rod type)
Cable operation
Left-hand operation
10 X 15 mm (0.39 X 0.59 in)

2-8

Item Standard Limit

Friction plates

Thickness
Plate quantity

Thickness
Plate quantity

Clutch plates

Thickness
Plate quantity
Max. warpage

Clutch springs

Free length
Spring quantity

Transmission

Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios

1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear

Max. main axle runout
Max. drive axle runout

ENGINE SPECIFICATIONS

2.92 X 3.08 mm (0.115 X 0.121 in)
8

3.42 X 3.58 mm (0.135 X 0.141 in)
1

1.9 X 2.1 mm (0.075 X 0.083 in)
8

50 mm (1.97 in)
6

Constant mesh, 6-speed
Spur gear
68/43 (1.581)
Chain drive
44/16 (2.750)
Left-foot operation

35/14 (2.500)
35/19 (1.842)
30/20 (1.500)
28/21 (1.333)
30/25 (1.200)
29/26 (1.115)

SPEC

2.82 mm
(0.111 in)

3.32 mm
(0.131 in)

0.1 mm
(0.004 in)

0.08 mm
(0.003 in)

0.08 mm
(0.003 in)

Shifting mechanism

Shift mechanism type
Max. shift fork guide bar bending

Installed shift rod length

Air filter type Dry element
Fuel pump

Pump type
Model (manufacturer)
Output pressure

Guide bar

260 mm (10.2 in)

Electrical
4SV (MITSUBISHI)
20 kPa (0.2 kg/cm

2-9

2

, 2.8 psi)

0.1 mm
(0.004 in)

Item Standard Limit

Carburetors

Model (manufacturer) X quantity
Throttle cable free play (at the
flange of the throttle grip)
ID mark
Main jet

Main air jet
Jet needle

Needle jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw turns out
Valve seat size
Starter jet 1
Starter jet 2
Throttle valve size
Fuel level (above the line on the
float chamber)

ENGINE SPECIFICATIONS

BSR37 (MIKUNI) X 4
3 X 5 mm (0.12 X 0.20 in)

5LV5 40
Carburetors 1 and 4: #132.5
Carburetors 2 and 3: #130
#80
Carburetor 1 and 4: 5D129-3/5
Carburetor 2 and 3: 5D130-3/5
P-OM
#85

1.0
#15

0.9

0.9

0.9

2.0

1.5
#42.5

0.8
#115

3.0 X 4.0 mm (0.118 X 0.157 in)

SPEC

Max. EXUP cable free play (at the
EXUP valve pulley)

1.5 mm (0.059 in)

2-10

CHASSIS SPECIFICATIONS

Item Standard Limit

Frame

Frame type
Caster angle
Trail

Front wheel

Wheel type
Rim

Size
Material

Wheel travel
Wheel runout

Max. radial wheel runout
Max. lateral wheel runout

Rear wheel

Wheel type
Rim

Size
Material

Wheel travel
Wheel runout

Max. radial wheel runout
Max. lateral wheel runout

CHASSIS SPECIFICATIONS

Double cradle
26_
104 mm (4.09 in)

Cast wheel
17 X MT3.50

Aluminum
140 mm (5.51 in)

SSS

SSS

Cast wheel
17 X MT5.50

Aluminum
135 mm (5.31 in)

SSS

SSS

SPEC

SSS
SSS
SSS

SSS

SSS
SSS
SSS

1 mm
(0.04 in)

0.5 mm
(0.02 in)

SSS

SSS
SSS
SSS

1 mm
(0.04 in)

0.5 mm
(0.02 in)

Front tire

Tire type
Size
Model (manufacturer)

Tire pressure (cold)

0 X 90 kg
90 X 201 kg
High-speed riding

Min. tire tread depth

Tubeless
120/70 ZR17 (58W)
MEZ4Y FRONT (METZELER)
BT020F U (BRIDGESTONE)

2

250 kPa (2.5 kgf/cm
250 kPa (2.5 kgf/cm
250 kPa (2.5 kgf/cm

, 36 psi)

2

, 36 psi)

2

, 36 psi)

SSS

SSS
SSS
SSS

SSS
SSS
SSS

1.0 mm
(0.04 in)

2-11