Yamaha XVS13AWC, XVS13CTWC, XVS13CTW, XVS13AW Service Manual
Yamaha Service Manual
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XVS13AW(C)
XVS13CTW(C)
SERVICE MANUAL
LIT-11616-20-42 3D8-28197-10
EAS20050
XVS13AW(C)/XVS13CTW(C)
SERVICE MANUAL
©2006 by Yamaha Motor Corporation, U.S.A.
First edition, August 2006
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-11616-20-42
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
to the vehicle operator, a bystander or a person checking or repairing the vehicle.
CAUTION:
NOTE:
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.
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
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequentially.
1
3
4
7
5
6
2
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
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®)
16.Replace the part
91011
E
G
M
12 13 14
B
LS
M
15 16
LT
New
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 THE FI SYSTEM................................................................. 1-2
FI SYSTEM ............................................................................................... 1-3
INSTRUMENT FUNCTIONS..................................................................... 1-4
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..................................... 1-6
BEARINGS AND OIL SEALS.................................................................... 1-7
CIRCLIPS.................................................................................................. 1-7
CHECKING THE CONNECTIONS.................................................................. 1-8
1
SPECIAL TOOLS............................................................................................ 1-9
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
1
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame. This
information will be needed to order spare parts.
IDENTIFICATION
1
1-1
FEATURES
EAS20170
FEATURES
EAS3D81037
OUTLINE OF THE 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 airfuel 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.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1. Air temperature sensor
2. Engine trouble warning light
3. Front cylinder intake air pressure sensor
4. Rear cylinder intake air pressure sensor
5. Rear cylinder ignition coil
6. Front cylinder ignition coil
7. Throttle position sensor
8. Spark plug
9. Speed sensor
10.Lean angle sensor
11.Relay unit (fuel pump relay)
12.Fuel pump
13.ECU (engine control unit)
14.O
sensor
2
15161718819
15.Rear cylinder injector
16.ISC (idle speed control) unit
17.Crankshaft position sensor
18.Front cylinder injector
19.Coolant temperature sensor
1-2
FEATURES
EAS3D81038
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 46.1 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel 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 fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel 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, air temperature sensor,
coolant temperature sensor, lean angle sensor, speed sensor and O
mine the injection 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.
Illustration is for reference only.
1
C
4
Rear
A
Front
2
3
sensor enable the ECU to deter-
2
65
7
8
10
9
15
B
1. Fuel pump
2. Fuel injector
3. Ignition coil
4. ECU (engine control unit)
5. Air temperature sensor
6. Lean angle sensor
7. ISC (idle speed control) unit
8. Throttle position sensor
9. O
sensor
2
10.Coolant temperature sensor
11.Catalytic converter
12.Crankshaft position sensor
13.Intake air pressure sensor
11
14
13
12
14.Throttle body
15.Air filter case
A. Fuel system
B. Air system
C. Control system
1-3
FEATURES
EAS3D81033
INSTRUMENT FUNCTIONS
Multi-function meter unit
EWA3D81011
WARNING
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit.
1
1. Speedometer
2. Odometer/tripmeter/fuel reserve
tripmeter/clock
2
Speedometer
1
1. Speedometer
The speedometer shows the riding speed.
When the key is turned to “ON”, the speedometer needle will sweep once across the speed
range and then return to zero in order to test the
electrical circuit.
Odometer, tripmeter, and fuel reserve tripmeter modes
The multi-function meter unit is equipped with
the following:
• a speedometer (which shows the riding 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 on the fuel reserve)
•a clock
• a self-diagnosis device
• a brightness control mode
NOTE:
Be sure to turn the key to “ON” before using the
“SELECT” switch “ / ” and “RESET” switch,
except for setting the brightness control mode.
1
SELECT
RESET
1. “SELECT” switch “ / ”
2. “RESET” switch
2
1
1. Odometer/tripmeter/fuel reserve
tripmeter/clock
Push the “ ” side of the “SELECT” switch to
switch the display between the odometer mode
“ODO”, the tripmeter modes “TRIP 1” and “TRIP
2” and the clock mode in the following order:
ODO → TRIP 1 → TRIP 2 → Clock → ODO
NOTE:
Push the “ ” side of the “SELECT” switch to
switch the display in the reverse order.
If the fuel level warning light comes on, 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 “ ” side of the “SELECT” switch to switch the display between the
various tripmeter, odometer, and clock modes in
the following order:
F-TRIP → TRIP 1 → TRIP 2 → Clock → ODO →
F-TRIP
1-4
FEATURES
NOTE:
Push the “” side of the “SELECT” switch to
switch the display in the reverse order.
To reset a tripmeter, select it by pushing the “”
or “” side of the “SELECT” switch, and then
push the “RESET” switch 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).
Clock mode
1
1. Clock
Push the “RESET” switch for less than one second to display the clock for five seconds, regardless of the currently selected display mode.
To set the clock:
1. Push the “” or “” side of the “SELECT”
switch to change the display to the clock
mode.
2. Push the “” side of the “SELECT” switch
and the “RESET” switch together for at least
two seconds.
3. When the hour digits start flashing, push the
“” or “” side of the “SELECT” switch to
set the hours.
4. Push the “RESET” switch, and the minute
digits will start flashing.
5. Push the “” or “” side of the “SELECT”
switch to set the minutes.
6. Push the “RESET” switch and then release it
to start the clock.
If the odometer/tripmeter/clock display indicates
any error codes, note the code number, and
then check the vehicle. Refer to “FUEL INJEC-
TION SYSTEM” on page 8-31.
ECA3D81016
CAUTION:
If the display indicates an error code, the vehicle should be checked as soon as possible
in order to avoid engine damage.
Brightness control mode
1
2
1. Speedometer panel
2. Brightness level
This function allows you to adjust the brightness
of the speedometer panel to suit the outside
lighting conditions.
To set the brightness:
1. Turn the key to “OFF”.
2. Push and hold the “” side of the “SELECT”
switch.
3. Turn the key to “ON”, and then release the
“SELECT” switch after five seconds or more.
4. Push the “” or “” side of the “SELECT”
switch to select the desired brightness level.
5. Push the “RESET” switch to confirm the selected brightness level. The display will return
to the odometer, tripmeter or clock mode.
Self-diagnosis device
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
odometer/tripmeter/clock display will indicate a
two-digit error code (e.g., 12, 13, 14).
1-5
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 1-9.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” 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.
1-6
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.
1-7
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
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.
Analog pocket tester
YU-03112-C
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)
1-8
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 numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.
Tool name/Tool No. Illustration
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
Tappet adjusting tool
90890-04154
YM-04154
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
Reference
pages
1-8, 5-64, 8-73,
8-74, 8-75,
8-79, 8-80,
8-81, 8-82,
8-83, 8-84,
8-85, 8-86,
8-87, 8-88,
8-89, 8-90
3-5, 3-6
3-6
3
3-7
Timing light
90890-03141
Inductive clamp timing light
YU-03141
YU-44456
3-10
1-9
SPECIAL TOOLS
Tool name/Tool No. Illustration
Compression gauge
90890-03081
Engine compression tester
YU-33223
Oil filter wrench
90890-01469
YM-01469
Belt tension gauge
90890-03170
Rear drive belt tension gauge
YM-03170
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
Reference
pages
3-11
3-12
66.8
3-25
3-26, 4-61
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
Rotor holding tool
90890-01235
Universal magneto & rotor holder
YU-01235
4-54, 4-56
4-54, 4-56
4-56, 4-57
5-15, 5-21,
5-22
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
5-16
1-10
SPECIAL TOOLS
Tool name/Tool No. Illustration
Weight
90890-01084
YU-01083-3
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attachment
90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1
Reference
pages
5-16
YU-01083-3
5-28, 5-33
5-28, 5-33
Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
5-29
5-29
5-29
1-11
SPECIAL TOOLS
Tool name/Tool No. Illustration
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
Reference
pages
5-35
YU-01304
5-43, 5-44,
5-51, 5-54
5-43
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
Universal clutch holder
90890-04086
YM-91042
5-45, 5-71,
6-10
5-51, 5-55
1-12
SPECIAL TOOLS
Tool name/Tool No. Illustration
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984
Reference
pages
6-3
YU-24460-01
6-3
YU-33984
Mechanical seal installer
90890-04078
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driver
90890-04058
Bearing driver 40 mm
YM-04058
Pressure gauge
90890-03153
YU-03153
Fuel pressure adapter
90890-03176
YM-03176
6-10
6-10
7-11
7-11
1-13
SPECIAL TOOLS
Tool name/Tool No. Illustration
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
Reference
pages
7-11
8-83
1-14
SPECIAL TOOLS
1-15
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 .................................... 2-24
ENGINE .................................................................................................. 2-24
CHASSIS ................................................................................................ 2-25
2
LUBRICATION SYSTEM CHART AND DIAGRAMS ................................... 2-27
ENGINE OIL LUBRICATION CHART ..................................................... 2-27
LUBRICATION DIAGRAMS.................................................................... 2-29
COOLING SYSTEM DIAGRAMS.................................................................. 2-37
CABLE ROUTING......................................................................................... 2-43
GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model XVS13AW 3D81 (USA)
XVS13AWC 3D82 (California)
XVS13AW 3D83 (CDN)
XVS13CTW 5S61 (USA)
XVS13CTWC 5S62 (California)
XVS13CTW 5S63 (CDN)
Dimensions
Overall length 2490 mm (98.0 in)
Overall width 980 mm (38.6 in)
Overall height XVS13AW(C) 1115 mm (43.9 in)
XVS13CTW(C) 1520 mm (59.8 in)
Seat height 715 mm (28.1 in)
Wheelbase 1690 mm (66.5 in)
Ground clearance 145 mm (5.71 in)
Minimum turning radius 3500 mm (137.8 in)
Weight
With oil and fuel XVS13AW(C) 303.0 kg (668 lb)
XVS13CTW(C) 323.0 kg (712 lb)
Maximum load XVS13AW(C) 210 kg (463 lb)
XVS13CTW(C) 190 kg (419 lb)
2-1
ENGINE SPECIFICATIONS
EAS20290
ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, SOHC
Displacement 1304.0 cm³
Cylinder arrangement V-type 2-cylinder
Bore × stroke 100.0 × 83.0 mm (3.94 × 3.27 in)
Compression ratio 9.50 :1
Standard compression pressure (at sea level) 1450 kPa/400 r/min (206.2 psi/400 r/min) (14.5
kgf/cm²/400 r/min)
Minimum–maximum 1200–1500 kPa (170.7–213.3 psi) (12.0–15.0
kgf/cm²)
Starting system Electric starter
Fuel
Recommended fuel XVS13AW(C) Unleaded gasoline only
(USA/California)
XVS13AW Regular unleaded gasoline only
(CDN)
XVS13CTW(C) Unleaded gasoline only
(USA/California)
XVS13CTW Regular unleaded gasoline only
(CDN)
Fuel tank capacity 18.5 L (4.89 US gal) (4.07 Imp.gal)
Fuel reserve amount 3.7 L (0.98 US gal) (0.81 Imp.gal)
Engine oil
Lubrication system Wet sump
Type YAMALUBE 4 (20W40) or SAE20W40
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount 3.70 L (3.91 US qt) (3.26 Imp.qt)
Without oil filter cartridge replacement 3.20 L (3.38 US qt) (2.82 Imp.qt)
With oil filter cartridge replacement 3.40 L (3.59 US qt) (2.99 Imp.qt)
Oil filter
Oil filter type Cartridge (paper)
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.09–0.19 mm (0.0035–0.0075 in)
Limit 0.26 mm (0.0102 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.13 mm (0.0024–0.0051 in)
Limit 0.20 mm (0.0079 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 391.0–489.0 kPa (56.7–70.9 psi) (3.91–4.89
kgf/cm²)
2-2
ENGINE SPECIFICATIONS
Cooling system
Radiator capacity (including all routes) 2.10 L (2.22 US qt) (1.85 Imp.qt)
Radiator capacity 0.55 L (0.58 US qt) (0.48 Imp.qt)
Coolant reservoir capacity (up to the maximum level
mark) 0.45 L (0.48 US qt) (0.40 Imp.qt)
Radiator cap opening pressure 93.3–122.7 kPa (13.5–17.8 psi) (0.93–1.23
kgf/cm²)
Valve relief pressure 4.9 kPa (0.7 psi) (0.05 kgf/cm²)
Thermostat
Model/manufacturer 1AE/YAMAHA
Valve opening temperature 80.5–83.5 °C (176.9–182.3 °F)
Valve full open temperature 95.0 °C (203.0 °F)
Valve lift (full open) 8.0 mm (0.31 in)
Radiator core
Width 197.0 mm (7.76 in)
Height 320.0 mm (12.60 in)
Depth 22.0 mm (0.87 in)
Water pump
Water pump type Single suction centrifugal pump
Reduction ratio 70/45 × 17/26 (1.017)
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug (s)
Manufacturer/model NGK/LMAR7A-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Volume 44.20–46.40 cm³ (2.70–2.83 cu.in)
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Chain drive (left and right)
Camshaft journal diameter 20.959–20.980 mm (0.8252–0.8260 in)
Camshaft lobe dimensions
Intake A 42.988–43.088 mm (1.6924–1.6964 in)
Limit 42.888 mm (1.6885 in)
Intake B 37.045–37.145 mm (1.4585–1.4624 in)
Limit 36.945 mm (1.4545 in)
Exhaust A 43.156–43.256 mm (1.6991–1.7030 in)
Limit 43.056 mm (1.6951 in)
Exhaust B 37.118–37.218 mm (1.4613–1.4653 in)
2-3
ENGINE SPECIFICATIONS
Limit 37.018 mm (1.4574 in)
A
B
Timing chain
Model/number of links 98XRH2010–132M/132
Tensioning system Automatic
Rocker arm/rocker arm shaft
Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in)
Rocker arm shaft outside diameter 11.976–11.991 mm (0.4715–0.4721 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.042 mm (0.0004–0.0017 in)
Limit 0.095 mm (0.0037 in)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.09–0.13 mm (0.0035–0.0051 in)
Exhaust 0.14–0.18 mm (0.0055–0.0071 in)
Valve dimensions
Valve head diameter A (intake) 35.90–36.10 mm (1.4134–1.4213 in)
Valve head diameter A (exhaust) 31.90–32.10 mm (1.2559–1.2638 in)
A
Valve seat width C (intake) 1.00–1.20 mm (0.0394–0.0472 in)
Valve seat width C (exhaust) 1.00–1.20 mm (0.0394–0.0472 in)
C
Valve margin thickness D (intake) 1.15–1.45 mm (0.0453–0.0571 in)
Valve margin thickness D (exhaust) 1.15–1.45 mm (0.0453–0.0571 in)
D
Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in)
Limit 5.945 mm (0.2341 in)
Valve stem diameter (exhaust) 5.960–5.975 mm (0.2346–0.2352 in)
Limit 5.930 mm (0.2335 in)
Valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in)
Limit 6.050 mm (0.2382 in)
Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in)
2-4
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