Yamaha FZS6W, FZS8WC Service Manual

FZS6W

4S8-28197-10

SERVICE MANUAL

LIT-11616-20-60

FZS6WC

EAS20050

or unauthorized use without the written

permission of Yamaha Motor Corporation,

FZS6W/FZS6WC

SERVICE MANUAL

©2006 by Yamaha Motor

Corporation, U.S.A.

First edition, Octover 2006

All rights reserved. Any reproduction

U.S.A. is expressly prohibited.

Printed inU.S.A.

P/N LIT-11616-20-60

EAS20070

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. 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.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is 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 Yamaha 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
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. 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:

• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS20080

IMPORTANT MANUAL 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

WARNING

CAUTION:

NOTE:

the vehicle operator, a bystander or a person checking or repairing the vehicle.

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

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

to

EAS20090

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 and each chapter is divided into sections. The current section
title is shown at the top of each page “1”.

• Sub-section titles appear in smaller print than the section title “2”.

• To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.

• Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disas­sembly step “4”.

• Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.

• A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc “6”.

• Jobs requiring more information (such as special tools and technical data) are described sequen­tially “7”.

EAS20100

SYMBOLS

The following symbols are used in this manual
for easier understanding.

NOTE:

The following symbols are not relevant to every
vehicle.

123

456

T

.

R

.

78

16.Replace the part

91011

E

G

12 13 14

B

LS

15 16

LT

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10.Gear oil

11.Molybdenum-disulfide oil

12.Wheel-bearing grease

13.Lithium-soap-based grease

14.Molybdenum-disulfide grease

15.Apply locking agent (LOCTITE®)

New

M

M

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHASSIS

ENGINE

1

2

3

4

5

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

6

7

8

9

GENERAL INFORMATION

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

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

MODEL LABEL.......................................................................................1-1

FEATURES ...................................................................................................1-2

OUTLINE OF FI SYSTEM ......................................................................1-2

FI SYSTEM.............................................................................................1-3

INSTRUMENT FUNCTIONS ..................................................................1-4

IMPORTANT INFORMATION .......................................................................1-7

PREPARATION FOR REMOVAL AND DISASSEMBLY .......................... 1-7

REPLACEMENT PARTS.........................................................................1-7

GASKETS, OIL SEALS AND O-RINGS..................................................1-7

LOCK WASHERS/PLATES AND COTTER PINS ...................................1-7

BEARINGS AND OIL SEALS ................................................................. 1-8

CIRCLIPS ...............................................................................................1-8

CHECKING THE CONNECTIONS ...............................................................1-9

1

SPECIAL TOOLS........................................................................................1-10

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is
stamped into the right side of the steering
head pipe.

EAS20150

MODEL LABEL

The model label “1” is affixed to the frame. This
information will be needed to order spare
parts.

IDENTIFICATION

1-1

FEATURES

EAS20170

FEATURES

EAS4S81003

OUTLINE OF FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti­mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera­ture.
In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combus­tion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in
the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con­ditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man­ner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions. Furthermore, the air induction sys­tem (AI system) has been placed under computer control together with the FI system in order to
realize cleaner exhaust gases.

1. Ignition coil

2. Air filter case

3. Intake air temperature sensor

4. Fuel delivery hose

5. Fuel tank

6. Fuel pump

7. Intake air pressure sensor

8. Throttle position sensor

9. Fuel injector

10.Catalytic converter

11.Crankshaft position sensor

1-2

12.Coolant temperature sensor

13.Spark plug

14.Pressure regulator

15.Battery

16.ECU

17.Fuel injection system relay

18.Engine trouble warning light

19.Lean angle sensor

20.O

sensor

2

FEATURES

EAS4S81004

FI SYSTEM

The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel

2

pressure that is applied to the injector at only 250 kPa (2.5 kg/cm
ing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be
injected into the intake manifold only during the time the passage remains open. Therefore, the
longer the length of time the injector is energized (injection duration), the greater the volume of fuel
that is supplied. Conversely, the shorter the length of time the injector is energized (injection dura­tion), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake tempera­ture sensor, coolant temperature sensor and O

sensor enable the ECU to determine the injection

2

duration. The injection timing is determined through the signals from the crankshaft position sensor.
As a result, the volume of fuel that is required by the engine can be supplied at all times in accor­dance with the driving conditions.

). Accordingly, when the energiz-

1. Fuel pump

2. Pressure regulator

3. Fuel injector

4. Throttle body

5. Intake air temperature sensor

6. Throttle position sensor

7. Intake air pressure sensor

8. ECU

9. Coolant temperature sensor

10.Crankshaft position sensor

11.O

sensor

2

A. Fuel system
B. Control system

1-3

FEATURES

EAS4S81005

INSTRUMENT FUNCTIONS

1. Coolant temperature display/air intake tem­perature display

2. Speedometer

3. Tachometer

4. Odometer/tripmeter/fuel reserve tripmeter

5. “SELECT” button

6. “RESET” button

7. Clock

8. Fuel meter

EWA4S81002

WARNING

Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit.

Tachometer

1. Tachometer

2. Tachometer red zone.

The electric tachometer allows the rider to
monitor the engine speed and keep it within
the ideal power range.
When the key is turned to “ON”, the tachome­ter needle will sweep once across the r/min
range and then return to zero r/min in order to
test the electrical circuit.

ECA4S81004

CAUTION:

Do not operate the engine in the tachome­ter red zone.
Red zone: 14000 r/min and above

Clock mode

The multi-function meter unit is equipped with
the following:

• a speedometer (which shows the riding
speed)

• a tachometer (which shows engine speed)

• an odometer (which shows the total distance
traveled)

• two tripmeters (which show the distance trav­eled since they were last set to zero)

• a fuel reserve tripmeter (which shows the
distance traveled since the left segment of
the fuel meter started flashing)

•a clock

• a fuel meter

• a coolant temperature display

• an air intake temperature displaya self-diag­nosis device

• an LCD and tachometer brightness control
mode

NOTE:

• Be sure to turn the key to “ON” before using
the “SELECT” and “RESET” buttons.

• To switch the speedometer and odometer/
tripmeter displays between kilometers and
miles, press the “SELECT” button for at least
one second.

1. Clock

2. Speedometer

The clock is displayed when the key is turned
to “ON”. In addition, the clock can be displayed
for 10 seconds by pushing the “SELECT” but­ton when the main switch is in the “OFF” or
“LOCK” position.
To set the clock
1 Turn the key to “ON”.

2. Push the “SELECT” button and “RESET”
button together for at least two seconds.

3. When the hour digits start flashing, push
the “RESET” button to set the hours.

4. Push the “SELECT” button, and the minute
digits will start flashing.

5. Push the “RESET” button to set the min­utes.

6. Push the “SELECT” button and then
release it to start the clock.

1-4

FEATURES

Odometer and tripmeter modes

1. Odometer/tripmeter/fuel reserve tripmeter

Push the “SELECT” button to switch the dis­play between the odometer mode “ODO” and
the tripmeter modes “TRIP A” and “TRIP B” in
the following order:
“TRIP A” → “TRIP B” → “ODO” → “TRIP A”
When the fuel amount in the fuel tank
decreases to 3.4 L (0.90 US gal) (0.75
Imp.gal), the left segment of the fuel meter will
start flashing, and the odometer display will
automatically change to the fuel reserve trip­meter mode “F TRIP” and start counting the
distance traveled from that point. In that case,
push the “SELECT” button to switch the dis­play between the various tripmeter and odom­eter modes in the following order:
“F-TRIP” → “TRIP A” → “TRIP B” → “ODO” →
“F-TRIP”
To reset a tripmeter, select it by pushing the
“SELECT” button, and then push the “RESET”
button for at least one second. If you do not
reset the fuel reserve tripmeter manually, it will
reset itself automatically and the display will
return to the prior mode after refueling and
traveling 5 km (3 mi).

Fuel meter

NOTE:

This fuel meter is equipped with a self-diagno­sis system. If the electrical circuit is defective,
the following cycle will be repeated until the
malfunction is corrected: “E” (Empty), “F” (Full)
and symbol “ ” will flash eight times, then go
off for approximately 3 seconds. If this occurs,
have a Yamaha dealer check the electrical cir­cuit.

Coolant temperature mode

1. Coolant temperature display

The coolant temperature display indicates the
temperature of the coolant.
Push the “RESET” button to switch the coolant
temperature display to the air intake tempera­ture display.

NOTE:

When the coolant temperature display is
selected, “C” is displayed for one second, and
then the coolant temperature is displayed.

ECA4S81009

CAUTION:

Do not operate the engine if it is over­heated.

Air intake temperature mode

1. Fuel meter

The fuel meter indicates the amount of fuel in
the fuel tank. The display segments of the fuel
meter disappear towards “E” (Empty) as the
fuel level decreases. When only one segment
is left near “E”, refuel as soon as possible.

1. Air intake temperature display

The air intake temperature display indicates
the temperature of the air drawn into the air fil­ter case. Push the “RESET” button to switch
the coolant temperature display to the air
intake temperature display.

1-5

FEATURES

NOTE:

• Even if the air intake temperature is set to be
displayed, the coolant temperature warning
light comes on when the engine overheats.

• When the key is turned to “ON”, the coolant
temperature is automatically displayed, even
if the air intake temperature was displayed
prior to turning the key to “OFF”.

• When the air intake temperature display is
selected, “A” is displayed for one second,
and then the air intake temperature is dis­played.

Self-diagnosis device

4. Push the “RESET” button to select the
desired brightness level.

5. Push the “SELECT” button to confirm the
selected brightness level. The display will
return to the odometer or tripmeter mode.

1. Error code display

This model is equipped with a self-diagnosis
device for various electrical circuits.
If any of those circuits are defective, the engine
trouble warning light will come on, and then the
display will indicate a two-digit error code (e.g.,
11, 12, 13).

LCD and tachometer brightness control mode

1. Tachometer panel

2. Tachometer needle

3. LCD

4. Brightness level

This function allows you to adjust the bright­ness of the LCD and the tachometer panel and
needle to suit the outside lighting conditions.
To set the brightness

1. Turn the key to “OFF”.

2. Push and hold the “SELECT” button.

3. Turn the key to “ON”, and then release the
“SELECT” button after five seconds.

1-6

EAS20180

IMPORTANT INFORMATION

EAS20190

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 "SPECIAL TOOLS" on page 1-10.

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.

IMPORTANT INFORMATION

EAS20210

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.

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.

EAS20200

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.

1. Oil

2. Lip

3. Spring

4. Grease

EAS20220

LOCK WASHERS/PLATES AND COTTER
PINS

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.

1-7

EAS20230

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu­facturer’s marks or numbers are visible. When
installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appro­priate.

ECA13300

CAUTION:

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

IMPORTANT INFORMATION

EAS20240

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 “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.

1-8

EAS20250

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.

CHECKING THE CONNECTIONS

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

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.

3. Check:

• All connections

Loose connection → Connect properly.

NOTE:

If the pin “1” 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)

1-9

SPECIAL TOOLS

EAS20260

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.

NOTE:

• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

• For others, use part number starting with “90890-”.

Tool name/Tool No. Illustration

Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B

Flywheel puller attachment
90890-04089
Crankshaft protector
YM-33282

Sheave holder
90890-01701
Primary clutch holder
YS-01880-A

Piston pin puller set
90890-01304
Piston pin puller
YU-01304

Reference

pages

5-30

5-30

5-30, 5-31, 5­32, 5-34

5-62

Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01

Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984

6-3

6-3

1-10

SPECIAL TOOLS

Tool name/Tool No. Illustration

Steering nut wrench
90890-01403
Spanner wrench
YU-33975

Damper rod holder
90890-01294
Damping rod holder set
YM-01300

T-handle
90890-01326
YM-01326

Oil filter wrench
90890-01426
YU-38411

Reference

pages

3-26, 4-53

4-45, 4-47

4-45, 4-47

3-13

Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7

Fork seal driver attachment (ø43)
90890-01374
Replacement 43 mm
YM-A5142-3

Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456

Compression gauge
90890-03081
Engine compression tester
YU-33223

4-47, 4-48

4-47

3-7

3-11

1-11

SPECIAL TOOLS

Tool name/Tool No. Illustration

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

Pressure gauge
90890-03153
YU-03153

Oil pressure adapter H
90890-03139

Fuel pressure adapter
90890-03176
YM-03176

Reference

pages

1-9, 5-38, 8-65,
8-66, 8-67, 8-71,
8-72, 8-73, 8-74,
8-75, 8-76, 8-77,
8-78, 8-79, 8-80,
8-81, 8-82

3-14, 7-6

3-14

7-6

Valve spring compressor
90890-04019
YM-04019

Valve spring compressor attachment
90890-04108
Valve spring compressor adapter 22 mm
YM-04108

Middle driven shaft bearing driver
90890-04058
Bearing driver 40 mm
YM-04058

Mechanical seal installer
90890-04078
Water pump seal installer
YM-33221-A

5-21, 5-27

5-21, 5-27

6-12

6-12

1-12

SPECIAL TOOLS

Tool name/Tool No. Illustration

Universal clutch holder
90890-04086
YM-91042

Valve lapper
90890-04101
Valve lapping tool
YM-A8998

Valve guide remover (ø4)
90890-04111
Valve guide remover (4.0 mm)
YM-04111

Valve guide installer (ø4)
90890-04112
Valve guide installer (4.0 mm)
YM-04112

Reference

pages

5-49, 5-51

3-5

5-23

5-23

Valve guide reamer (ø4)
90890-04113
Valve guide reamer (4.0 mm)
YM-04113

Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487

Yamaha bond No. 1215
(Three bond No.1215®)
90890-85505

Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927

5-23

8-74

5-32, 5-35, 5­58, 6-12

7-7

1-13

SPECIFICATIONS

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

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

CHASSIS SPECIFICATIONS........................................................................2-9

ELECTRICAL SPECIFICATIONS...............................................................2-12

TIGHTENING TORQUES............................................................................2-15

GENERAL TIGHTENING TORQUE SPECIFICATIONS....................... 2-15

ENGINE TIGHTENING TORQUES ......................................................2-16

CHASSIS TIGHTENING TORQUES ....................................................2-20

LUBRICATION POINTS AND LUBRICANT TYPES ..................................2-22

ENGINE ................................................................................................2-22

CHASSIS ..............................................................................................2-23

2

LUBRICATION SYSTEM CHART AND DIAGRAMS .................................2-25

ENGINE OIL LUBRICATION CHART ...................................................2-25

LUBRICATION DIAGRAMS ..................................................................2-27

COOLING SYSTEM DIAGRAMS ...............................................................2-39

CABLE ROUTING ......................................................................................2-47

GENERAL SPECIFICATIONS

EAS20280

GENERAL SPECIFICATIONS

Model

Model 4S82 (U.S.A.)

Dimensions

Overall length 2095 mm (82.5 in)
Overall width 750 mm (29.5 in)
Overall height 1210 mm (47.6 in)
Seat height 795 mm (31.3 in)
Wheelbase 1440 mm (56.7 in)
Ground clearance 145 mm (5.71 in)
Minimum turning radius 2800 mm (110.2 in)

Weight

With oil and fuel 207.0 kg (456 lb) (FZS6W)

Maximum load 189 kg (417 lb) (FZS6WC)

4S83 (California)

208.0 kg (459 lb) (FZS6WC)

190 kg (419 lb) (FZS6W)

2-1

ENGINE SPECIFICATIONS

EAS20290

ENGINE SPECIFICATIONS

Engine

Engine type Liquid cooled 4-stroke, DOHC
Displacement 600.0 cm³
Cylinder arrangement Forward-inclined parallel 4-cylinder
Bore × stroke 65.5 × 44.5 mm (2.58 × 1.75 in)
Compression ratio 12.20 :1
Standard compression pressure (at sea level) 1550 kPa/400 r/min (220.5 psi/400 r/min) (15.5

kgf/cm²/400 r/min)

Minimum–maximum 1300–1650 kPa (184.9–234.7 psi) (13.0–16.5

kgf/cm²)

Starting system Electric starter

Fuel

Recommended fuel Unleaded gasoline only
Fuel tank capacity 19.4 L (5.13 US gal) (4.27 Imp.gal)
Fuel reserve amount 3.6 L (0.95 US gal) (0.79 Imp.gal)

Engine oil

Lubrication system Wet sump
Type YAMALUBE 4, SAE10W30 or SAE 20W40
Recommended engine oil grade API service SG type or higher, JASO standard

MA

Engine oil quantity

Total amount 3.40 L (3.59 US qt) (2.99 Imp.qt)
Without oil filter cartridge replacement 2.50 L (2.64 US qt) (2.20 Imp.qt)
With oil filter cartridge replacement 2.80 L (2.96 US qt) (2.46 Imp.qt)
Oil pressure 240 kPa at 6,600 r/min

(2.4 kg/cm² at 6,600 r/min)
(2.4 bar at 6,600 r/min)
(34.1 psi at 6,600 r/min)

Oil filter

Oil filter type Formed

Oil pump

Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance 0.030–0.090 mm (0.0012–0.0035 in)
Limit 0.15 mm (0.0059 in)
Outer-rotor-to-oil-pump-housing clearance 0.030–0.080 mm (0.0012–0.0032 in)
Limit 0.150 mm (0.0059 in)
Bypass valve opening pressure 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20

kgf/cm²)

Relief valve operating pressure 450.0–550.0 kPa (65.3–79.8 psi) (4.50–5.50

kgf/cm²)

Pressure check location Main gallery

Cooling system

Radiator capacity (including all routes) 2.00 L (2.11 US qt) (1.76 Imp.qt)
Radiator capacity 0.60 L (0.63 US qt) (0.53 Imp.qt)
Coolant reservoir capacity (up to the maximum

level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt)
Radiator cap opening pressure 93–123 kPa (13.2–17.5 psi) (0.93–1.23 kgf/

cm²)

Radiator core

Width 300.0 mm (11.81 in)
Height 188.0 mm (7.40 in)
Depth 24.0 mm (0.94 in)

2-2

ENGINE SPECIFICATIONS

Water pump

Water pump type Single suction centrifugal pump
Reduction ratio 86/44 × 31/31 (1.955)
Max. impeller shaft tilt 0.15 mm (0.006 in)

Spark plug (s)

Manufacturer/model NGK/CR9EK
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)

Cylinder head

Volume 10.33–10.93 cm³ (0.63–0.67 cu.in)
Warpage limit 0.05 mm (0.0020 in)

Camshaft

Drive system Chain drive (right)
Camshaft cap inside diameter 23.008–23.029 mm (0.9058–0.9067 in)
Camshaft journal diameter 22.967–22.980 mm (0.9042–0.9047 in)
Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Limit 0.080 mm (0.0032 in)

Camshaft lobe dimensions

Intake A 32.450–32.550 mm (1.2776–1.2815 in)
Limit 32.400 mm (1.2756 in)
Intake B 24.950–25.050 mm (0.9823–0.9862 in)
Limit 24.900 mm (0.9803 in)
Exhaust A 32.450–32.550 mm (1.2776–1.2815 in)
Limit 32.400 mm (1.2756 in)
Exhaust B 24.950–25.050 mm (0.9823–0.9862 in)
Limit 24.900 mm (0.9803 in)

Camshaft runout limit 0.060 mm (0.0024 in)

Timing chain

Model/number of links 92RH2015/120
Tensioning system Automatic

Valve clearance (cold)

Intake 0.13–0.20 mm (0.0051–0.0079 in)
Exhaust 0.23–0.30 mm (0.0091–0.0118 in)

2-3

ENGINE SPECIFICATIONS

Valve dimensions

Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in)
Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in)

Valve face width B (intake) 1.140–1.980 mm (0.0449–0.0780 in)
Valve face width B (exhaust) 1.140–1.980 mm (0.0449–0.0780 in)

Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)

Valve margin thickness D (intake) 0.60–0.80 mm (0.0236–0.0315 in)
Limit 0.5 mm (0.02 in)
Valve margin thickness D (exhaust) 0.60–0.80 mm (0.0236–0.0315 in)
Limit 0.5 mm (0.02 in)

Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in)
Limit 3.950 mm (0.1555 in)
Valve stem diameter (exhaust) 3.960–3.975 mm (0.1559–0.1565 in)
Limit 3.935 mm (0.1549 in)
Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in)
Limit 4.042 mm (0.1591 in)
Valve guide inside diameter (exhaust) 4.000–4.012 mm (0.1575–0.1580 in)
Limit 4.042 mm (0.1591 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.040 mm (0.0016 in)

Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)

2-4

ENGINE SPECIFICATIONS

Limit 1.6 mm (0.06 in)

Valve spring

Inner spring
Free length (intake) 37.04 mm (1.46 in)
Limit 35.20 mm (1.39 in)
Free length (exhaust) 41.79 mm (1.65 in)
Limit 39.70 mm (1.56 in)
Installed length (intake) 30.02 mm (1.18 in)
Installed length (exhaust) 36.12 mm (1.42 in)
Spring rate K1 (intake) 10.50 N/mm (59.96 lb/in) (1.07 kgf/mm)
Spring rate K2 (intake) 17.00 N/mm (97.07 lb/in) (1.73 kgf/mm)
Spring rate K1 (exhaust) 30.26 N/mm (172.78 lb/in) (3.09 kgf/mm)
Spring rate K2 (exhaust) 49.53 N/mm (282.82 lb/in) (5.05 kgf/mm)
Installed compression spring force (intake) 69–79 N (15.51–17.76 lbf) (7.04–8.06 kgf)
Installed compression spring force (exhaust) 160–184 N (35.97–41.36 lbf) (16.32–18.76

kgf)

Spring tilt (intake) 2.5 °/1.6 mm (0.06 in)
Spring tilt (exhaust) 2.5 °/1.8 mm (0.07 in)

Winding direction (intake) Counter clockwise
Winding direction (exhaust) Clockwise
Outer spring
Free length (intake) 38.40 mm (1.51 in)
Limit 36.50 mm (1.44 in)
Installed length (intake) 32.52 mm (1.28 in)
Spring rate K1 (intake) 20.80 N/mm (118.77 lb/in) (2.12 kgf/mm)
Spring rate K2 (intake) 33.30 N/mm (190.14 lb/in) (3.40 kgf/mm)
Installed compression spring force (intake) 114–132 N (25.63–29.67 lbf) (11.62–13.46

kgf)

Spring tilt (intake) 2.5 °/1.7 mm (0.07 in)
Winding direction (intake) Clockwise

Cylinder

Bore 65.500–65.510 mm (2.5787–2.5791 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)

Piston

Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
Limit 0.05 mm (0.0020 in)
Diameter D 65.475–65.490 mm (2.5778–2.5783 in)
Height H 4.0 mm (0.16 in)

2-5

ENGINE SPECIFICATIONS

Offset 0.50 mm (0.0197 in)
Offset direction Intake side
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in)
Limit 15.971 mm (0.6288 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in)
Limit 0.072 mm (0.0028 in)

Piston ring

Top ring

Ring type Barrel
Dimensions (B × T) 0.90 × 2.45 mm (0.04 × 0.10 in)

End gap (installed) 0.25–0.35 mm (0.0098–0.0138 in)
Limit 0.60 mm (0.0236 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.115 mm (0.0045 in)

2nd ring

Ring type Taper
Dimensions (B × T) 0.80 × 2.50 mm (0.03 × 0.10 in)

End gap (installed) 0.70–0.80 mm (0.0276–0.0315 in)
Limit 1.15 mm (0.0453 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.125 mm (0.0049 in)

Oil ring

Dimensions (B × T) 1.50 × 2.00 mm (0.06 × 0.08 in)

End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in)

Connecting rod

Oil clearance (using plastigauge®) 0.028–0.052 mm (0.0011–0.0020 in)
Limit 0.08 mm (0.0032 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green

2-6

ENGINE SPECIFICATIONS

Crankshaft

Width A 51.850–52.550 mm (2.04–2.06 in)
Width B 268.80–270.00 mm (10.58–10.63 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in)

Big end radial clearance 0.028–0.052 mm (0.0011–0.0020 in)
Small end free play 0.32–0.50 mm (0.01–0.02 in)
Journal oil clearance (using plastigauge®) 0.034–0.058 mm (0.0013–0.0023 in)
Limit 0.10 mm (0.0039 in)
Bearing color code 0.White 1.Black 2.Brown 3.Green 4.Yellow

Clutch

Clutch type Wet, multiple-disc
Clutch release method Outer pull, rack and pinion pull
Clutch release method operation Cable operation
Clutch lever free play 10.0–15.0 mm (0.39–0.59 in)
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.80 mm (0.1102 in)
Plate quantity 6 pcs
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Plate quantity 2 pcs
Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in)
Plate quantity 7 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch plate thickness 2.20–2.40 mm (0.087–0.094 in)
Plate quantity 1 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch spring free length 55.00 mm (2.17 in)
Limit 52.30 mm (2.06 in)
Spring quantity 6 pcs

Transmission

Transmission type Constant mesh 6-speed
Primary reduction system Spur gear
Primary reduction ratio 86/44 (1.955)
Secondary reduction system Chain drive
Secondary reduction ratio 46/16 (2.875)
Operation Left foot operation

Gear ratio

1st 37/13 (2.846)
2nd 37/19 (1.947)
3rd 28/18 (1.556)
4th 32/24 (1.333)
5th 25/21 (1.190)
6th 26/24 (1.083)
Main axle runout limit 0.02 mm (0.0008 in)
Drive axle runout limit 0.02 mm (0.0008 in)

2-7