YAMAHA XV1600AL, XV1600ALC SERVICE MANUALS

XV16AL/XV16ALC XV16ATL/XV16ATLC

SERVICEMANUAL

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

All rights reserved. Any reproduction or unauthorized 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.

WARNING

CAUTION:

NOTE:

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

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.

1				2
GEN				SPEC
INFO
3				4
CHK				CHAS
ADJ
5				6
ENG				CARB
7				8
ELEC	–	+		TRBL
				SHTG
9				0
A				B
C				D
	T
	.
	R
	.
E				F
G		H		I
E			G	M
J		K		L
B			LS	M
M				N
LT				New

********

SYMBOLS

The following symbols are not relevant to every vehicle.

Symbols 1 to 8 indicate the subject of each chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Chassis

5 Engine

6 Carburetor

7 Electrical system

8 Troubleshooting

Symbols 9 to F indicate the following.

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 G to L in the exploded diagrams indicate the types of lubricants and lubrication points.

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.

********

TABLE OF CONTENTS

GENERAL INFORMATION	GEN	1
	INFO
SPECIFICATIONS	SPEC	2
PERIODIC CHECKS AND		3
ADJUSTMENTS	CHK
	ADJ
CHASSIS	CHAS	4
ENGINE	ENG	5
CARBURETION	CARB	6
	–	+
ELECTRICAL SYSTEM	ELEC	7

TROUBLESHOOTING
		TRBL		8
		SHTG

GEN

INFO

CONTENTS

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION ................................................................	1-1
VEHICLE IDENTIFICATION NUMBER ..................................................	1-1
MODEL CODE	1-1	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			GEN
					INFO
			EAS00014
			GENERAL INFORMATION
			MOTORCYCLE IDENTIFICATION
			EAS00017
			VEHICLE IDENTIFICATION NUMBER
			The vehicle identification number 1 is
			stamped into the right side of the steering
1
			head pipe.
			EAS00018
			MODEL CODE
			The model code label 1 is affixed to the
			frame. This information will be needed to
			order spare parts.

1 - 1

FEATURES

EAS00019

GEN INFO

	FEATURES
	Twin spark plugs
	For this model, two spark plugs are incor-
	porated in each cylinder.
	By using two spark plugs, the combustion	1
	time in the combustion chamber is short-
	ened 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.

Self-diagnosis device

This model is equipped with a self-diagno- sis device that has four functions.

The engine trouble indicator light will come on or flash if trouble occurs in an engine monitoring circuit.

		Num-
Circuit	Indicator lights	ber of
		flashes
Throttle	Engine trouble indica-	3
position	tor light 1
sensor
Speed	Engine trouble indica-	4
sensor	tor light 1
Solenoid	Engine trouble indica-	6
	tor light 1
Fuel level	Fuel level indicator light	8
meter	2

1 - 2 Refer to “SELF-DIAGNOSIS” in chapter 7.

FEATURES

Auto decompression mechanism

GEN INFO

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.

1

1Decompression solenoid

2Decompression solenoid rod

3Decompression connector

4Decompression lever

5Decompression push rod

6Decompression cam

7Pin

8Spring

9Camshaft

1 - 3

FEATURES

Operation

GEN INFO

	1. When the starter switch is pushed, elec-
	tricity is run to the decompression sole-
	noid 1 causing it to push out the
	decompression solenoid rod 2.
	2. When the decompression solenoid rod is
	pushed out, the decompression connec-
		1
	tor 3 moves the decompression levers
	4 in the direction indicated by the
	arrows, and then the levers push the
	decompression rods 5 toward the cam-
	shaft side.

3.The decompression cam 6 is pushed in the direction indicated by the arrow, and then the pin 7 raises the projection of 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.

1 - 4

FEATURES

Hydraulic valve lifters

GEN INFO

		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 follow-
		ing: mechanical noise is reduced, the camshaft action on the valves remains unaffected by
		engine speed or temperature, and the valve timing is kept stable.
1			1Plunger
			2Oil reservoir
			3Check valve spring
			4Check valve
			5Spring retainer
			6High-pressure chamber
			7Plunger spring
			8Valve lifter body
			9Oil supply inlet
			0Push rod cup
			APlunger retaining clip
			BValve 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 posi-

tion, 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

GEN

IMPORTANT INFORMATION INFO

EAS00020

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly,
remove all dirt, mud, dust, and foreign	1
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.

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						GEN
								INFO
				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
1
				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, lubri-
				cate the oil seal lips with a light coat of
				lithium soap base grease. Oil bearings
				liberally when installing, if appropriate.
				1Oil seal
				CAUTION:
				ACHTUNG:
				Do not spin bearings with compressed air
				because this will damage the bearing sur-
				faces.
				1Bearing

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.

4Shaft

1 - 7

CHECKING THE CONNECTIONS

EAS00026

GEN INFO

CHECKING THE CONNECTIONS

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

	1.	Disconnect:
	• lead
			1
	• 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 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 revitalizer available at most part stores.

1 - 8

SPECIAL TOOLS

EAS00027

GEN INFO

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.
	1		When placing an order, refer to the list provided below to avoid any mistakes.
			Tool No.	Tool name/Function	Illustration
			YM-01080-A	Flywheel puller
				This tool is used to remove the generator
				rotor.
			T-handle	T-handle
			YM-01326	Damper rod holder
			Damper rod	These tools are used to hold the cartridge
			holder	cylinder when loosening or tightening the
			YM-1300-1	cartridge cylinder bolt.
				Fuel level gauge
			YM-01312-A
				This tool is used to measure the fuel level
				in the float chamber.
				Timing light
			YM-33277-A
				This tool is used to check the ignition tim-
				ing.
				Belt tension gauge
			YM-03170
				This tool is used to measure the drive belt
				slack.
			Fork seal	Fork seal driver weight
			driver weight	Adapter
			YM-33963	These tools are used to install the front
			Adapter
			YM-8020	fork’s oil seal and dust seal.
				Dynamic spark tester
			YM-34487
				This tool is used to check the ignition sys-
				tem components.
				Valve spring compressor
			YM-04019
				This tool is used to remove or install the
				valve assemblies.
				1 - 9

	SPECIAL TOOLS			GEN
				INFO
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.
								1
	Valve guide installer
YM-4065-A
	This tool is used to install the valve
	guides.
	Valve guide reamer
YM-4066
	This tool is used to rebore the new valve
	guides.
	Universal clutch holder
YM-91042	This tool is used to hold the clutch boss
	when removing or installing the clutch
	boss nut.
	Sheave holder
YS-01880	This tool is used to hold the generator
	rotor when removing or installing the gen-
	erator rotor bolt, generator shaft bolt or
	pickup coil rotor bolt.
	Piston pin puller
YU-01304
	This tool is used to remove the piston
	pins.
	Micrometer (75 ~ 100 mm)
YU-03009
	This tool is used to measure the piston
	skirt diameter.
	Cylinder bore gauge (50 ~ 100 mm)
YU-03017
	This tool is used to measure the cylinder
	bore.
	Pocket tester
YU-03112
	This tool is used to check the electrical
	system.

1 - 10

			SPECIAL TOOLS			GEN
						INFO
		Tool No.	Tool name/Function	Illustration
		Compression	Compression gauge
		gauge
		YU-33223
		Compression	These tools are used to measure engine
		gauge adapter
		YU-33223-3	compression.
1
			Steering nut wrench
		YU-33975
			This tool is used to loosen or tighten the
			steering stem ring nuts.
			Oil filter wrench
		YU-38411
			This tool is needed to loosen or tighten
			the oil filter cartridge.
			Inductive tachometer
		YU-8036-A
			This tool is used to check engine speed.
			Quick Gasket
		ACC-11001-05-	This sealant is used to seal two mating
		01
			surfaces (e. g., crankcase mating sur-
			faces).
			Oil pressure gauge
		90890-03153
			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					2
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)			----
2		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,	196 kg (432 lb): XV16A			----
		passenger, and accessories)	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 cm3

----

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

52 kPa (390 mm Hg, 15.4 in Hg)

----

2

speed

Standard compression pressure

1,200 kPa

----

(at sea level)

(12.0 kgf/cm2, 171 psi) at 200 r/min

Fuel

Recommended fuel

Unleaded fuel (for USA)

----

Regular unleaded gasoline (for CDN)

----

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

----

30

40

50

60˚F

Yamalube 4 (20W40) or SAE 20W40 type

SE motor oil (40˚F/5˚C or above)

(Non-Friction modified)

0

5

10

15˚C

Quantity

Total amount

5.0 L (4.4 Imp qt, 5.3 US qt)

----

Without oil filter cartridge

3.7 L (3.3 Imp qt, 3.9 US qt)

----

replacement

With oil filter cartridge replace-

4.1 L (3.6 Imp qt, 4.3 US qt)

----

ment

Oil pressure (hot)

60 kPa (0.6 kgf/cm2, 8.5 psi) at 900 r/min

----

Relief valve opening pressure

0.60 MPa (6.0 kgf/cm2, 85 psi)

----

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

----

(0.8 ~ 1.2 kgf/cm2, 11.3 ~ 17.1 psi)

2 - 2

ENGINE SPECIFICATIONS SPEC

		Item				Standard	Limit
		Engine oil pump
		Oil pump type				Trochoidal	----
		Inner rotor to outer rotor tip clear-				0.00 ~ 0.12 mm (0.000 ~ 0.005 in)	0.17 mm
		ance					(0.007 in)
		Inner rotor outer rotor 2 to oil pump				0.03 ~ 0.08 mm (0.001 ~ 0.003 in)	0.13 mm
		housing clearance (feed pump)					(0.005 in)
		Inner rotor outer rotor 1 to oil				0.06 ~ 0.11 mm (0.002 ~ 0.004 in)	0.16 mm
		pump housing clearance					(0.006 in)
		(scavenging pump)
		Transfer oil pump
2
		Oil pump type				Trochoidal
		Inner rotor to outer rotor tip clear-				0.07 ~ 0.12 mm (0.003 ~ 0.005 in)	0.17 mm
		ance					(0.007 in)
		Inner rotor outer rotor to oil pump				0.03 ~ 0.08 mm (0.001 ~ 0.003 in)	0.16 mm
		housing clearance					(0.006 in)
		Starting system type				Electric starter
		Spark plugs
		Model				DPR7EA-9/X22EPR-U9	----
		Manufacturer				NGK/DENSO	----
		Quantity				4	----
		Spark plug gap				0.8 ~ 0.9 mm (0.031 ~ 0.035 in)	----
		Cylinder heads
		Max. warpage				----	0.10 mm
							(0.004 in)
		Camshafts
		Drive system				Gear drive	----
		Crankcase hole inside diameter				25.000 ~ 25.021 mm	----
						(0.9843 ~ 0.9851 in)
		Camshaft cover hole inside diam-				28.000 ~ 28.021 mm	----
		eter				(1.1024 ~ 1.1032 in)
		Camshaft journal diameter				24.937 ~ 24.950 mm	----
		(crankcase side)				(0.9818 ~ 0.9823 in)
		Camshaft journal diameter				27.967 ~ 27.980 mm	----
		(camshaft cover side)				(1.1011 ~ 1.1016 in)
		Camshaft to crankcase clearance				0.050 ~ 0.084 mm (0.0020 ~ 0.0033 in)	----
		Camshaft to camshaft cover clear-				0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in)	----
		ance
		Camshaft intake cam dimensions

A

B

2 - 3

ENGINE SPECIFICATIONS

SPEC

Item

Standard

Limit

Measurement A

36.594 ~ 36.649 mm

36.494 mm

(1.4407 ~ 1.4429 in)

(1.4368 in)

Measurement B

31.950 ~ 32.050 mm

31.850 mm

(1.2579 ~ 1.2618 in)

(1.2539 in)

Camshaft exhaust cam dimen-

sions

A

2

B

Measurement A

36.554 ~ 36.654 mm

36.454 mm

(1.4391~ 1.4431 in)

(1.4352 in)

Measurement B

31.950 ~ 32.050 mm

31.850 mm

(1.2579 ~ 1.2618 in)

(1.2539 in)

Rocker arms, Rocker arm shafts

Rocker arm inside diameter

15.000 ~ 15.018 mm

15.036 mm

(0.5906 ~ 0.5913 in)

(0.5920 in)

Rocker arm shaft outside diameter

14.981 ~ 14.991 mm

14.97 mm

(0.5898 ~ 0.5902 in)

(0.5894 in)

Rocker arm to rocker arm shaft

0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in)

0.08 mm

clearance

(0.003 in)

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

B

C

A

Seat Width

D

Head Diameter

Face Width

Margin Thickness

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

(0.079 in)

Exhaust

0.9 ~ 1.1 mm (0.035 ~ 0.043 in)

2.0 mm

(0.079 in)

2 - 4

ENGINE SPECIFICATIONS SPEC

Item

Standard

Limit

Valve margin thickness D

Intake

0.7 ~ 1.3 mm (0.028 ~ 0.051 in)

0.4 mm

(0.016 in)

Exhaust

0.7 ~ 1.3 mm (0.028 ~ 0.051 in)

0.4 mm

(0.016 in)

Valve stem diameter

Intake

5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in)

5.945 mm

(0.2341 in)

Exhaust

5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in)

5.920 mm

(0.2331 in)

2

Valve guide inside diameter

Intake

6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)

6.05 mm

(0.2382 in)

Exhaust

6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)

6.05 mm

(0.2382 in)

Valve stem-to-valve guide clear-

ance

Intake

0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)

0.08 mm

(0.0031 in)

Exhaust

0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)

0.1 mm

(0.004 in)

Valve stem runout

----

0.01 mm

(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
		(1.43 in)
Exhaust	38.26 mm (1.51 in)	36.26 mm
		(1.43 in)
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)	----

2 - 5

ENGINE SPECIFICATIONS SPEC

Item

Standard

Limit

Spring tilt

Intake	----			2.5˚ /2.4 mm
				(2.5˚/0.094 in)
					2
Exhaust	----			2.5˚ /2.4 mm
Winding direction (top view)				(2.5˚/0.094 in)
Intake	Counterclockwise			----
Exhaust	Counterclockwise			----

Outer springs
Free length
Intake	43.25 mm (1.70 in)	41.26 mm
		(1.62 in)
Exhaust	43.25 mm (1.70 in)	41.26 mm
		(1.62 in)
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	----
	(13.9 ~ 16.1 kgf, 30.6 ~ 35.5 lb)
Exhaust	139 ~ 161 N	----
	(13.9 ~ 16.1 kgf, 30.6 ~ 35.5 lb)
Spring tilt

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		SPEC
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)
2
		Valve lifter case inside diameter			22.990 ~ 23.010 mm	----
					(0.9051 ~ 0.9059 in)
		Valve lifter-to-valve lifter case			0.0156 ~ 0.0420 mm	----
		clearance			(0.0006 ~ 0.0017 in)
		Valve push rods
		Valve push rod length			293.45 ~ 293.95 mm	----
					(11.553 ~ 11.573 in)
		Valve push rod runout			0.3 mm (0.012 in)	----
		Cylinders
		Bore			95.000 ~ 95.010 mm	----
					(3.7402 ~ 3.7406 in)
		Max. taper			----	0.05 mm
						(0.0016 in)
		Max. out of round			----	0.05 mm
						(0.0016 in)
		Pistons
		Piston-to-cylinder clearance			0.025 ~ 0.050 mm (0.001 ~ 0.002 in)	0.15 mm
						(0.006 in)
		Diameter D			94.960 ~ 94.975 mm	----
					(3.7386 ~ 3.7392 in)

	H
D
Height H	5 mm (0.20 in)	----
Piston pin bore (in the piston)
Diameter	22.004 ~ 22.015 mm	22.045 mm
	(0.8663 ~ 0.8667 in)	(0.8679 in)
Offset	1.0 mm (0.04 in)	----
Piston pins
Outside diameter	21.991 ~ 22.000 mm	21.971 mm
	(0.8658 ~ 0.8661 in)	(0.8650 in)
Piston pin-to-piston pin bore	0.004 ~ 0.024 mm	0.074 mm
clearance	(0.00016 ~ 0.00094 in)	(0.0029 in)

2 - 7

ENGINE SPECIFICATIONS SPEC

Item

Standard

Limit

Piston rings

Top ring

B

T

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

(0.026 in)

2

Ring side clearance

0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)

0.12 mm

(0.0047 in)

2nd ring

B

T

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

(0.031 in)

Ring side clearance

0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in)

0.12 mm

(0.0047 in)

Oil ring

B

T

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

0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in)

----

clearance

Bearing color code

1 = Blue, 2 = Black, 3 = Brown,

----

4 = Green, 5 = Yellow.

Connecting rod length

191.95 ~ 192.05 mm (7.557 ~ 7.561 in)

Crankshaft

C

C

E

D

A

Width A

132.8 ~ 133.2 mm (5.228 ~ 5.244 in)

----

Max. runout C

0.04 mm

(0.0016 in)

Big end side clearance D

0.320 ~ 0.474 mm (0.013 ~ 0.019 in)

----

2 - 8

ENGINE SPECIFICATIONS SPEC

		Item	Standard	Limit
		Big end radial clearance E	0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in)	0.09 mm
				(0.0035 in)
		Crankshaft journal-to-crankshaft-	0.030 ~ 0.062 mm (0.0012 ~ 0.0024 in)	0.1 mm
		journal bearing clearance		(0.0040 in)
		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	----
2		Clutch cable free play (at the end	10 ~ 15 mm (0.39 ~ 0.59 in)	----
		of the clutch lever)
		Friction plates
		Thickness	2.9 ~ 3.1 mm (0.114 ~ 0.122 in)	2.8 mm
				(0.110 in)
		Plate quantity	9	----
		Clutch plates
		Thickness	2.2 ~ 2.4 mm (0.087 ~ 0.094 in)	----
		Plate quantity	8	----
		Max. warpage	----	0.2 mm
				(0.008 in)
		Clutch springs
		Free length	7 mm (0.276 in)	----
		Spring quantity	1	----
		Min. length		6.5 mm
				(0.256 in)
		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
				(0.003 in)
		Max. drive axle runout	----	0.08 mm
				(0.003 in)

2 - 9

	ENGINE SPECIFICATIONS		SPEC
Item	Standard			Limit
Shifting mechanism
Shift mechanism type	Guide bar			----
Max. shift fork guide bar bending	----			0.025 mm
				(0.001 in)
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			----			2
	(0.15 ~0.20 kgf/cm2, 2.1 ~ 2.8 psi)
Carburetor
Model (manufacturer) × quantity	BSR40 (MIKUNI) × 1			----
Throttle cable free play (at the	3 ~ 5 mm (0.12 ~ 0.20 in)			----
flange of the throttle grip)
ID mark	4WM1 00			----
	4WM2 10 (for California)			----
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-	2.0 ~ 3.0 mm (0.079 ~ 0.12 in)			----
ber mating surface)

2 - 10

			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 × MT3.00			----
2
		Material		Steel			----
		Wheel travel		140 mm (5.51 in)			----
		Wheel runout
		Max. radial wheel runout		----			1 mm
							(0.04 in)
		Max. lateral wheel runout		----			0.5 mm
							(0.02 in)
		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
							(0.04 in)
		Max. lateral wheel runout		----			0.5 mm
							(0.02 in)
		Front tire
		Tire type		With tube			----
		Size		130/90 - 16 67H			----
		Model (manufacturer)		D404FL (DUNLOP)/			----
				G703F (BRIDGESTONE)
		Tire pressure (cold)
		0 ~ 90 kg (0 ~ 198 lb)		250 kPa (2.5 kg/cm2, 36 psi)			----
		90 kg (198 lb) ~ Maximum load*		250 kPa (2.5 kg/cm2, 36 psi)			----
		High-speed riding		250 kPa (2.5 kg/cm2, 36 psi)			----
				* Load is the total weight of the cargo,
				rider, passenger and accessories.
		Min. tire tread depth		----			1.6 mm
							(0.06 in)

2 - 11