YAMAHA XV1600AL, XV1600ALC SERVICE MANUALS

XV16AL

XV16ALC

XV16ATL

SERVICE MANUAL

XV16ATLC

LIT-11616-12-56 4WM-28197-E0

EAS00001

XV16AL/XV16ALC

XV16ATL/XV16ATLC

SERVICE MANUAL

 1998 by Yamaha Motor Corporation, U.S.A.

First Edition, October 1998

rized use without the written permission of

Yamaha Motor Corporation, U.S.A. is expressly

prohibited.

Printed in U.S.A.

P/N LIT-11616-12-56

EAS00003

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 with 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.

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

NOTE:

Designs and specifications are subject to change without notice.

EAS00004

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!

WARNING

CAUTION:

NOTE:

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

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. 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”.

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.

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. Refer to “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 sequentially.

GEN

SPEC

INFO

CHK

CHAS

ADJ

ENG

CARB

********

SYMBOLS

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

1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Carburetor 7 Electrical system 8 Troubleshooting

1 to

8 indicate the subject of

–+

TRBL

ELEC

SHTG

GHI

Symbols

9 Serviceable with engine mounted 0 Filling fluid A Lubricant B Special tool C Tightening torque D Wear limit, clearance E Engine speed F Electrical data

Symbols

9 to

F indicate the following.

G to

L in the exploded diagrams

indicate the types of lubricants and lubrication points.

New

JKL

G Engine oil H Gear oil I Molybdenum disulfide oil J Wheel bearing grease K Lithium soap base grease L Molybdenum disulfide grease

Symbols

M to

N in the exploded diagrams

indicate the following.

M Apply locking agent (LOCTITE). N Replace the part.

********

1 2 3 4 5 6 7 8

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHASSIS

ENGINE

GEN

INFO

SPEC

CHK ADJ

CHAS

ENG

CARBURETION

ELECTRICAL SYSTEM

TROUBLESHOOTING

CARB

–+

ELEC

TRBL

SHTG

GEN

INFO

CONTENTS

GENERAL INFORMATION

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

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

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

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

IMPORTANT INFORMATION ......................................................................1-6

PREPARATION FOR REMOVAL AND DISASSEMBLY .......................1-6

REPLACEMENT PARTS ........................................................................ 1-6

GASKETS, OIL SEALS AND O-RINGS ................................................ 1-6

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

BEARINGS AND OIL SEALS ................................................................ 1-7

CIRCLIPS ............................................................................................... 1-7

CHECKING THE CONNECTIONS .................................................................1-8

SPECIAL TOOLS ...........................................................................................1-9

MOTORCYCLE IDENTIFICATION

EAS00014

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

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

EAS00018

MODEL CODE

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

GEN

INFO

1 is

1 is affixed to the

1 - 1

GEN

FEATURES

EAS00019

FEATURES

Twin spark plugs

For this model, two spark plugs are incorporated in each cylinder. By using two spark plugs, the combustion time in the combustion chamber is shortened in an attempt to improve torque.

Speed sensor

The speed sensor is installed to the crankcase and it detects the number of passing gears while the vehicle is running in 5th gear and sends the information out as an electrical signal to the ignitor unit.

INFO

Self-diagnosis device

This model is equipped with a self-diagnosis device that has four functions. The engine trouble indicator light will come on or flash if trouble occurs in an engine monitoring circuit.

Circuit Indicator lights

Throttle position sensor

Speed sensor

Solenoid Engine trouble indica-

Fuel level meter

Refer to “SELF-DIAGNOSIS” in chapter 7.

1 - 2

Engine trouble indicator light 1

tor light 1

Fuel level indicator light 28

Number of

flashes

GEN

FEATURES

Auto decompression mechanism

The auto decompression mechanism occurs when the engine is started. When the engine is started, the decompression cam and pin raise the exhaust valve lifters, push the push rods, move the rocker arms, and lower the exhaust valves which compress the cylinder. When the cylinder is compressed, pressure is released immediately, resulting in smoother engine starting capabilities and smoother crankshaft revolutions.

INFO

1 Decompression solenoid 2 Decompression solenoid rod 3 Decompression connector 4 Decompression lever 5 Decompression push rod 6 Decompression cam 7 Pin 8 Spring 9 Camshaft

1 - 3

GEN

FEATURES

Operation

1. When the starter switch is pushed, electricity is run to the decompression solenoid decompression solenoid rod 2.

2. When the decompression solenoid rod is pushed out, the decompression connector 4 in the direction indicated by the arrows, and then the levers push the decompression rods shaft side.

1 causing it to push out the

3 moves the decompression levers

INFO

5 toward the cam-

3. The decompression cam the direction indicated by the arrow, and then the pin the decompression cam.

4. When the camshaft is rotated by the selftiming motor, the exhaust valve lifters 8 are lifted by the pin just before top dead center (TDC) and the exhaust valve push rod 9 and valve rocker arms are operated. Thus, opening the exhaust valve becomes easy.

5. When the engine starts and reaches a specific engine speed the decompression solenoid is turned off and the decompression system stops operating.

7 raises the projection of

6 is pushed in

1 - 4

GEN

FEATURES

Hydraulic valve lifters

Since the hydraulic valve-lifting mechanism maintains a valve clearance of zero, periodic valve clearance adjustments are unnecessary. The advantages of this system as compared to conventional techniques include the following: mechanical noise is reduced, the camshaft action on the valves remains unaffected by engine speed or temperature, and the valve timing is kept stable.

INFO

1 Plunger 2 Oil reservoir 3 Check valve spring 4 Check valve 5 Spring retainer 6 High-pressure chamber 7 Plunger spring 8 Valve lifter body 9 Oil supply inlet 0 Push rod cup A Plunger retaining clip B Valve push rod

The hydraulic valve-lifting system functions as follows:

1. As the camshaft rotates, the valve lifter is pushed up by the passing cam lobe.

2. Since the check valve 4 prevents the engine oil contained inside the high-pressure chamber from escaping, the plunger 1 moves up along with the valve lifter body 8 and pushes up the push rod, causing the valve to be lifted.

3. As the camshaft continues to rotate, the valve lifter moves back down to its original position, where it remains while the cam heel passes.

When a positive valve clearance is caused by either heat expansion of the cylinder head or engine oil leaking from the valve lifter during stage 2, the plunger, which no longer receives pressure from the push rod, is pushed up by the plunger spring 7. As a result, the valve clearance is zeroed and engine oil is allowed to return to the high-pressure chamber from the reservoir 2 through the check valve 4. When, on the contrary, a negative valve clearance occurs (this is the case when the cam heel is passing the valve lifter, but the rocker arm, pushed by the push rod, is lifting the valve), the plunger 1 continues to receive pressure from the valve push rod. As engine oil contained inside the high-pressure chamber leaks from the gaps between the valve lifter body 8 and the plunger 1 as well as between the valve lifter body 8 and the check valve 4, the plunger 1 moves down and the valve clearance is zeroed.

1 - 5

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 “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.

GEN

INFO

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 - 6

IMPORTANT INFORMATION

EAS00023

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 washer tabs and the cotter pin ends along a flat of the bolt or nut.

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, lubricate the oil seal lips with a light coat of lithium soap base grease. Oil bearings liberally when installing, if appropriate.

1 Oil seal

GEN

INFO

CAUTION:

ACHTUNG:

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

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

4 Shaft

1 - 7

CHECKING THE CONNECTIONS

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.

GEN

INFO

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)

Pocket tester

YU-03112

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 revital-

1 - 8

izer available at most part stores.

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. Tool name/Function Illustration

YM-01080-A Flywheel puller

This tool is used to remove the generator rotor.

T-handle YM-01326 Damper rod holder YM-1300-1

YM-01312-A

YM-33277-A

T-handle Damper rod holder These tools are used to hold the cartridge cylinder when loosening or tightening the cartridge cylinder bolt.

Fuel level gauge

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

Timing light

This tool is used to check the ignition timing.

YM-03170

Fork seal driver weight YM-33963 Adapter YM-8020

YM-34487

YM-04019

Belt tension gauge

This tool is used to measure the drive belt slack.

Fork seal driver weight Adapter

These tools are used to install the front fork’s oil seal and dust seal.

Dynamic spark tester

This tool is used to check the ignition system components.

Valve spring compressor

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

1 - 9

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Valve guide remover (6 mm)

YM-4064-A

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

GEN

INFO

YM-4065-A

YM-4066

YM-91042

YS-01880

Valve guide installer

This tool is used to install the valve guides.

Valve guide reamer

This tool is used to rebore the new valve guides.

Universal clutch holder

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

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

Piston pin puller

YU-01304

YU-03009

YU-03017

YU-03112

This tool is used to remove the piston pins.

Micrometer (75 ~ 100 mm)

This tool is used to measure the piston skirt diameter.

Cylinder bore gauge (50 ~ 100 mm)

This tool is used to measure the cylinder bore.

Pocket tester

This tool is used to check the electrical system.

1 - 10

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

INFO

Compression gauge YU-33223 Compression gauge adapter YU-33223-3

YU-33975

YU-38411

YU-8036-A

Compression gauge

These tools are used to measure engine compression.

Steering nut wrench

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

Oil filter wrench

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

Inductive tachometer

This tool is used to check engine speed.

Quick Gasket



ACC-11001-0501

90890-03153

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

Oil pressure gauge

This tool is used to measure the engine oil pressure.

1 - 11

SPEC

CONTENTS

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 ................................................... 2-21

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

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

CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ..........2-24

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

ENGINE OIL FLOW DIAGRAMS ................................................................ 2-26

TRANSFER GEAR OIL FLOW DIAGRAMS ................................................2-30

CABLE ROUTING .......................................................................................2-32

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Dimensions

Overall length 2,500 mm (98.4 in) ---Overall width 980 mm (38.6 in) ---Overall height 1,140 mm (44.9 in): XV16A ----

1,500 mm (59.1 in): XV16AT ---Seat height 710 mm (28.0 in) ---Wheelbase 1,685 mm (66.3 in) ---Minimum ground clearance 145 mm (5.71 in) ---Minimum turning radius 3,200 mm (126 in) ----

Weight

Wet (with oil and a full fuel tank) 332 kg (732 lb): XV16A ----

347 kg (765 lb): XV16AT ---Dry (without oil and fuel) 307 kg (678 lb): XV16A ----

322 kg (710 lb): XV16AT ---Maximum load (total of cargo, rider,

passenger, and accessories)

196 kg (432 lb): XV16A

181 kg (399 lb): XV16AT

----

2 - 1

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Engine

Engine type Air-cooled, 4-stroke, OHV ---Displacement 1,602 cm Cylinder arrangement V-type 2-cylinder ---Bore × stroke 95 × 113 mm (3.74 × 4.45 in) ---Compression ratio 8.3:1 ---Engine idling speed 850 ~ 950 r/min ---Vacuum pressure at engine idling

speed Standard compression pressure

(at sea level)

Fuel

Recommended fuel Unleaded fuel (for USA) ----

Fuel tank capacity

Total (including reserve) 20 L (17.6 Imp qt, 21.1 US qt) ---Reserve only 3.5 L (3.08 Imp qt, 3.70 US qt) ----

Engine oil

Lubrication system Dry sump ---Recommended oil

52 kPa (390 mm Hg, 15.4 in Hg) ----

1,200 kPa

(12.0 kgf/cm

Regular unleaded gasoline (for CDN) ----

, 171 psi) at 200 r/min

----

Quantity

Total amount 5.0 L (4.4 Imp qt, 5.3 US qt) ---Without oil filter cartridge

replacement With oil filter cartridge replace-

ment Oil pressure (hot) 60 kPa (0.6 kgf/cm Relief valve opening pressure 0.60 MPa (6.0 kgf/cm

Transfer gear oil

Recommended oil SAE80API “GL-4” hypoid gear oil ---Quantity 0.4 L (0.35 Imp qt, 0.42 US qt) ----

Oil ﬁlter

Oil ﬁlter type Cartridge (paper) ---Bypass valve opening pressure 80 ~ 120 kPa

40 50

10 15˚C

60˚F

Yamalube 4 (20W40) or SAE 20W40 type SE motor oil (40˚F/5˚C or above) (Non-Friction modiﬁed)

3.7 L (3.3 Imp qt, 3.9 US qt) ----

4.1 L (3.6 Imp qt, 4.3 US qt) ----

, 8.5 psi) at 900 r/min ----

, 85 psi) ----

(0.8 ~ 1.2 kgf/cm

, 11.3 ~ 17.1 psi)

----

2 - 2

ENGINE SPECIFICATIONS

Item Standard Limit

Engine oil pump

Oil pump type Trochoidal ---Inner rotor to outer rotor tip clear-

ance Inner rotor outer rotor 2 to oil pump

housing clearance (feed pump) Inner rotor outer rotor 1 to oil

pump housing clearance (scavenging pump)

Transfer oil pump

Oil pump type Trochoidal Inner rotor to outer rotor tip clear-

ance Inner rotor outer rotor to oil pump

housing clearance

Starting system type Electric starter Spark plugs

Model Manufacturer Quantity

Spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) ----

Cylinder heads

Max. warpage ---- 0.10 mm

Camshafts

Drive system Gear drive ---Crankcase hole inside diameter 25.000 ~ 25.021 mm

Camshaft cover hole inside diameter

Camshaft journal diameter (crankcase side)

Camshaft journal diameter (camshaft cover side)

Camshaft to crankcase clearance 0.050 ~ 0.084 mm (0.0020 ~ 0.0033 in) ---Camshaft to camshaft cover clear-

ance Camshaft intake cam dimensions

0.00 ~ 0.12 mm (0.000 ~ 0.005 in) 0.17 mm

0.03 ~ 0.08 mm (0.001 ~ 0.003 in) 0.13 mm

0.06 ~ 0.11 mm (0.002 ~ 0.004 in) 0.16 mm

0.07 ~ 0.12 mm (0.003 ~ 0.005 in) 0.17 mm

0.03 ~ 0.08 mm (0.001 ~ 0.003 in) 0.16 mm

DPR7EA-9/X22EPR-U9 NGK/DENSO 4

(0.9843 ~ 0.9851 in)

28.000 ~ 28.021 mm (1.1024 ~ 1.1032 in)

24.937 ~ 24.950 mm (0.9818 ~ 0.9823 in)

27.967 ~ 27.980 mm (1.1011 ~ 1.1016 in)

0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) ----

SPEC

(0.007 in)

(0.005 in)

(0.006 in)

(0.007 in)

(0.006 in)

(0.004 in)

----

2 - 3

ENGINE SPECIFICATIONS

Item Standard Limit

SPEC

Measurement A 36.594 ~ 36.649 mm

(1.4407 ~ 1.4429 in)

Measurement B 31.950 ~ 32.050 mm

(1.2579 ~ 1.2618 in)

Camshaft exhaust cam dimensions

Measurement A 36.554 ~ 36.654 mm

(1.4391~ 1.4431 in)

Measurement B 31.950 ~ 32.050 mm

(1.2579 ~ 1.2618 in)

Rocker arms, Rocker arm shafts

Rocker arm inside diameter 15.000 ~ 15.018 mm

(0.5906 ~ 0.5913 in)

Rocker arm shaft outside diameter 14.981 ~ 14.991 mm

(0.5898 ~ 0.5902 in)

Rocker arm to rocker arm shaft clearance

Valves, valve seats, valve guides

Valve clearance (cold)

Intake 0 ~ 0.04 mm (0 ~ 0.0016 in) ----

Exhaust 0 ~ 0.04 mm (0 ~ 0.0016 in) ---Valve dimensions

0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm

36.494 mm (1.4368 in)

31.850 mm (1.2539 in)

36.454 mm (1.4352 in)

31.850 mm (1.2539 in)

15.036 mm (0.5920 in)

14.97 mm (0.5894 in)

(0.003 in)

Head Diameter

Valve head diameter A

Intake 33.9 ~ 34.1 mm (1.3346 ~ 1.3425 in) ---Exhaust 27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in) ----

Valve face width B

Intake 1.3 ~ 2.3 mm (0.0512 ~ 0.0906 in) ---Exhaust 1.2 ~ 2.4 mm (0.0472 ~ 0.0945 in) ----

Valve seat width C

Intake 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) 2.0 mm

Exhaust 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) 2.0 mm

Face Width

2 - 4

Seat Width

Margin Thickness

(0.079 in)

ENGINE SPECIFICATIONS

Item Standard Limit

Valve margin thickness D

Intake 0.7 ~ 1.3 mm (0.028 ~ 0.051 in) 0.4 mm

Exhaust 0.7 ~ 1.3 mm (0.028 ~ 0.051 in) 0.4 mm

Valve stem diameter

Intake 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.945 mm

Exhaust 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 5.920 mm

Valve guide inside diameter

Intake 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.05 mm

Exhaust 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.05 mm

Valve stem-to-valve guide clear-

ance

Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm

Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.1 mm

Valve stem runout ---- 0.01 mm

SPEC

(0.016 in)

(0.2341 in)

(0.2331 in)

(0.2382 in)

(0.0031 in)

(0.004 in)

(0.0004 in)

Valve seat width

Intake 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) ---Exhaust 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) ----

Valve springs

Inner springs

Free length

Intake 38.26 mm (1.51 in) 36.26 mm

Exhaust 38.26 mm (1.51 in) 36.26 mm

Installed length (valve closed)

Intake 29.0 mm (1.14 in) ---Exhaust 29.0 mm (1.14 in) ----

Compressed spring force

(installed)

Intake 63 ~ 73 N (6.3 ~ 7.3 kgf, 13.9~ 16.1 lb) ---Exhaust 63 ~ 73 N (6.3 ~ 7.3 kgf, 13.9~ 16.1 lb) ----

(1.43 in)

2 - 5

ENGINE SPECIFICATIONS

Item Standard Limit

Spring tilt

Intake ---- 2.5˚ /2.4 mm

Exhaust ---- 2.5˚ /2.4 mm

Winding direction (top view)

Intake Counterclockwise ---Exhaust Counterclockwise ----

SPEC

(2.5˚/0.094 in)

Outer springs

Free length

Intake 43.25 mm (1.70 in) 41.26 mm

Exhaust 43.25 mm (1.70 in) 41.26 mm

Installed length (valve closed)

Intake 31.0 mm (1.22 in) ---Exhaust 31.0 mm (1.22 in) ----

Compressed spring force

(installed)

Intake 139 ~ 161 N

Exhaust 139 ~ 161 N

Spring tilt

(1.62 in)

----

(13.9 ~ 16.1 kgf, 30.6 ~ 35.5 lb)

----

(13.9 ~ 16.1 kgf, 30.6 ~ 35.5 lb)

Intake ---- 2.5˚ /2.4 mm

(2.5˚/0.094 in)

Exhaust ---- 2.5˚ /2.4 mm

(2.5˚/0.094 in)

2 - 6

ENGINE SPECIFICATIONS

Item Standard Limit

Winding direction (top view)

Intake Clockwise ---Exhaust Clockwise ----

Valve lifters

Valve lifter outside diameter 22.9680 ~ 22.9744 mm

(0.9043 ~ 0.9045 in)

Valve lifter case inside diameter 22.990 ~ 23.010 mm

(0.9051 ~ 0.9059 in)

Valve lifter-to-valve lifter case clearance

Valve push rods

Valve push rod length 293.45 ~ 293.95 mm

Valve push rod runout 0.3 mm (0.012 in) ----

Cylinders

Bore 95.000 ~ 95.010 mm

Max. taper ---- 0.05 mm

Max. out of round ---- 0.05 mm

Pistons

Piston-to-cylinder clearance 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) 0.15 mm

Diameter D 94.960 ~ 94.975 mm

0.0156 ~ 0.0420 mm (0.0006 ~ 0.0017 in)

(11.553 ~ 11.573 in)

(3.7402 ~ 3.7406 in)

(3.7386 ~ 3.7392 in)

SPEC

(0.0016 in)

(0.006 in)

----

Height H 5 mm (0.20 in) ---Piston pin bore (in the piston)

Diameter 22.004 ~ 22.015 mm

(0.8663 ~ 0.8667 in)

Offset 1.0 mm (0.04 in) ---Piston pins

Outside diameter 21.991 ~ 22.000 mm

(0.8658 ~ 0.8661 in)

Piston pin-to-piston pin bore

clearance

0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in)

2 - 7

22.045 mm (0.8679 in)

21.971 mm (0.8650 in)

0.074 mm (0.0029 in)

Piston rings

Top ring

Ring type Barrel ---Dimensions (B × T) 1.2 × 3.8 mm (0.047 × 0.150 in) ---End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.65 mm

Ring side clearance 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in) 0.12 mm

2nd ring

Ring type Taper ---Dimensions (B × T) 1.2 × 3.8 mm (0.047 × 0.150 in) ---End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.8 mm

Ring side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.12 mm

Oil ring

ENGINE SPECIFICATIONS

Item Standard Limit

SPEC

(0.026 in)

(0.0047 in)

(0.031 in)

(0.0047 in)

Dimensions (B × T) 2.5 × 3.4 mm (0.098 × 0.134 in) ---End gap (installed) 0.2 ~ 0.7 mm (0.008 ~ 0.028 in) ----

Connecting rods

Crankshaft pin-to-big end bearing clearance

Bearing color code 1 = Blue, 2 = Black, 3 = Brown,

Connecting rod length 191.95 ~ 192.05 mm (7.557 ~ 7.561 in)

Crankshaft

Width A 132.8 ~ 133.2 mm (5.228 ~ 5.244 in) ---Max. runout C 0.04 mm

Big end side clearance D 0.320 ~ 0.474 mm (0.013 ~ 0.019 in) ----

0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in) ----

4 = Green, 5 = Yellow.

(0.0016 in)

----

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ENGINE SPECIFICATIONS

Item Standard Limit

Big end radial clearance E 0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in) 0.09 mm

Crankshaft journal-to-crankshaftjournal bearing clearance

Clutch

Clutch type Wet, multiple disc ---Clutch release method Rack and pinion (pull rod type) ---Clutch release method operation Cable operation ---Operation Left-hand operation ---Clutch cable free play (at the end

of the clutch lever) Friction plates

Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm

Plate quantity 9 ---Clutch plates

Thickness 2.2 ~ 2.4 mm (0.087 ~ 0.094 in) ----

Plate quantity 8 ----

Max. warpage ---- 0.2 mm

Clutch springs

Free length 7 mm (0.276 in) ----

Spring quantity 1 ----

Min. length 6.5 mm

Transmission

Transmission type Constant mesh, 5-speed ---Primary reduction system Spur gear ---Primary reduction ratio 72/47 (1.532) ---Secondary reduction system Belt drive ---Secondary reduction ratio 35/32 × 70/33 (2.320) ---Operation Left-foot operation ---Gear ratios

1st gear 39/16 (2.437) ----

2nd gear 30/19 (1.578) ----

3rd gear 29/25 (1.160) ----

4th gear 29/32 (0.906) ----

5th gear 21/28 (0.750) ---Max. main axle runout ---- 0.08 mm

Max. drive axle runout ---- 0.08 mm

0.030 ~ 0.062 mm (0.0012 ~ 0.0024 in) 0.1 mm

10 ~ 15 mm (0.39 ~ 0.59 in) ----

SPEC

(0.0035 in)

(0.0040 in)

(0.110 in)

(0.008 in)

(0.256 in)

(0.003 in)

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ENGINE SPECIFICATIONS

Item Standard Limit

Shifting mechanism

Shift mechanism type Guide bar ---Max. shift fork guide bar bending ---- 0.025 mm

Shift fork thickness 6.26 ~ 6.39 mm (0.246 ~ 0.252 in) ----

Air ﬁlter type Dry element ---- Fuel pump

Pump type Electrical ---Model (manufacturer) 4WM (MITSUBISHI) ---Output pressure 15 ~ 20 kPa

(0.15 ~0.20 kgf/cm

Carburetor

Model (manufacturer) Throttle cable free play (at the

ﬂange of the throttle grip) ID mark 4WM1 00 ----

Main jet #165 ---Main air jet #60 ---Jet needle 6HDC26 ---Needle jet X-2 ---Pilot air jet #100 ---Pilot outlet 1.0 (XV16A), 1.1 (XV16AT) ---Pilot jet #35 ---Bypass 1 0.9 ---Bypass 2 1.0 ---Bypass 3 0.9 ---Pilot screw turns out 2-1/2 ---Valve seat size 2.0 ---Starter jet 1 #57.5 ---Starter jet 2 1.0 ---Butterﬂy valve size #110 ---Fuel level (below the ﬂoat cham-

ber mating surface)

× quantity BSR40 (MIKUNI)

3 ~ 5 mm (0.12 ~ 0.20 in) ----

4WM2 10 (for California) ----

2.0 ~ 3.0 mm (0.079 ~ 0.12 in) ----

, 2.1 ~ 2.8 psi)

× 1 ----

SPEC

(0.001 in)

----

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CHASSIS SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

Frame

Frame type Double cradle ---Caster angle 32˚ ---Trail 142 mm (5.59 in) ----

Front wheel

Wheel type Spoke wheel ---Rim

Size 16

Material Steel ---Wheel travel 140 mm (5.51 in) ---Wheel runout

Max. radial wheel runout ---- 1 mm

Max. lateral wheel runout ---- 0.5 mm

Rear wheel

Wheel type Spoke wheel ---Rim

Size 16 × MT3.50 ----

Material Steel ---Wheel travel 110 mm (4.33 in) ---Wheel runout

Max. radial wheel runout ---- 1 mm

Max. lateral wheel runout ---- 0.5 mm

Front tire

Tire type With tube ---Size 130/90 - 16 67H ---Model (manufacturer) D404FL (DUNLOP)/

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm

90 kg (198 lb) ~ Maximum load* 250 kPa (2.5 kg/cm

High-speed riding 250 kPa (2.5 kg/cm

Min. tire tread depth ---- 1.6 mm

× MT3.00 ----

(0.04 in)

(0.02 in)

(0.04 in)

(0.02 in)

G703F (BRIDGESTONE)

, 36 psi) ----

* Load is the total weight of the cargo,

rider, passenger and accessories.

(0.06 in)

----

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