Yamaha YBR125ED User Manual
2005
YBR125ED
3D9-F8197-E0
SERVICE MANUAL
EAS00000
YBR125ED 2005
SERVICE MANUAL
©2005 by Yamaha Motor Co., Ltd.
First edition, January 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002
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.
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:
_
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
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
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.
12
GEN
SPEC
INFO
34
CHK
CHAS
ADJ
56
ENG
78
CARB
EAS00009
SYMBOLS
The following symbols are not relevant to
every vehicle. Symbols 1 to 8 indicate the
subject of each chapter.
General information
1
Specifications
2
Periodic checks and adjustments
3
Chassis
4
Engine
5
Carburetor
6
Electrical system
7
Troubleshooting
8
–+
TRBL
ELEC
SHTG
90
AB
CD
T
.
R
.
EF
GHI
LS
G
M
M
E
JKL
B
Symbols 9 to F indicate the following.
Serviceable with engine mounted
9
Filling fluid
0
Lubricant
A
Special tool
B
Tightening torque
C
Wear limit, clearance
D
Engine speed
E
Electrical data
F
Symbols G to L in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Engine oil
G
Gear oil
H
Molybdenum-disulfide oil
I
Wheel-bearing grease
J
Lithium-soap-based grease
K
Molybdenum-disulfide grease
L
MN
LT
New
Symbols M to N in the exploded diagrams
indicate the following.
®
Apply locking agent (LOCTITE
M
Replace the part
N
)
EAS00011
– +
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
1
2
3
4
5
CARBURETOR
ELECTRICAL SYSTEM
TROUBLESHOOTING
CARB
ELEC
TRBL
SHTG
6
7
8
CHAPTER 1
GENERAL INFORMATION
GEN
INFO
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2
REPLACEMENT PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-3
BEARINGS AND OIL SEALS ....................................................................1-3
CIRCLIPS ..................................................................................................1-3
CHECKING THE CONNECTIONS
SPECIAL TOOLS
............................................................................................1-5
............................................................................1-1
.........................................................................1-2
..................................................................1-4
1
1
VEHICLE IDENTIFICATION
EAS00014
GENERAL INFORMATION
VEHICLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the right side of the steering head
pipe.
EAS00018
MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare
parts.
GEN
INFO
1 - 1
IMPORTANT INFORMATION
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
GEN
INFO
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 - 2
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
tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
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-based grease.
Oil bearings liberally when installing, if appropriate.
Oil seal
1
GEN
INFO
CAUTION:
_
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
Bearing
1
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.
Shaft
4
1 - 3
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.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
_
If the pin 1 on the terminal is flattened, bend it
up.
GEN
INFO
4. Connect:
• lead
• coupler
• connector
NOTE:
_
Make sure all connections are tight.
5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112, 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.
1 - 4
GEN
SPECIAL TOOLS
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
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 No. Tool name/Function Illustration
INFO
Slide hammer bolt
90890-01083
YU-01083-1
Weight
90890-01084
YU-01083-3
90890-01135
YU-01135-B
90890-04019
YM-04019
Pot
90890-01274
YU-90058
YU-90059
Bolt
90890-01275
YU-90060
Slide hammer bolt
Weight
These tools are used to remove or install
the rocker arm shafts.
Crankcase separating tool
This tool is used to remove the crankshaft.
Valve spring compressor
This tool is used to remove or install the
valve assemblies.
Crankshaft installer pot
Crankshaft installer bolt
These tools are used to install the crankshaft.
Adapter
90890-01278
YU-90063
Spacer
90890-04081
YM-91044
90890-01304
YU-01304
Adapter (M12)
Spacer (crankshaft installer)
These tools are used to install the crankshaft.
Piston pin puller set
This tool is used to remove the piston pin.
1 - 5
GEN
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
Tappet adjusting tool
90890-01311
YM-08035-A
This tool is used to adjust the valve clearance.
Fuel level gauge
90890-01312
YM-01312-A
This gauge is used to measure the fuel
level in the float chamber.
T-handle
90890-01326
YM-01326
This tool is used to hold the 14 mm hexagon nut/socket wrench when removing or
installing the damper rod.
INFO
90890-01362
YU-33270-B
Weight
90890-01367
YM-A9409-7
YM-A5142-4
Attachment
90890-01400
90890-01403
YU-33975
90890-01701
YS-01880-A
Flywheel puller
This tool is used to remove the generator
rotor.
Fork seal driver weight
Fork seal driver attachment (ø30)
These tools are used to install the oil
seal, dust seal, and the outer tube bushing of the front fork legs.
Steering nut wrench
This tool is used to loosen or tighten the
steering ring nuts.
Sheave holder
This tool is used to hold the A.C. magneto
rotor when loosening or tightening the
A.C. magneto rotor nut.
90890-03079
YM-34483
Thickness gauge
This tool is used to measure the valve
clearance.
1 - 6
GEN
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
Compression gauge
90890-03081
YU-33223
These tools are used to measure the
engine compression.
Pocket tester
90890-03112
YU-03112-C
This tool is used to check the electrical
system.
Timing light
90890-03141
YU-03141
This tool is used to check the ignition timing.
INFO
90890-03158
90890-04086
YM-91042
90890-04097
YM-04097
90890-04098
YM-04098
Carburetor angle driver
This tool is used to turn the air screw
when adjusting the engine idling speed.
Universal clutch holder
This tool is needed to hold the clutch
boss when removing or installing the
boss nut.
Valve guide remover (ø5)
This tool is needed to remove and install
the valve guides.
Valve guide installer (ø5)
This tool is needed to install the valve
guides.
90890-04099
YM-04099
Valve guide reamer (ø5)
This tool is needed to rebore the new
valve guides.
1 - 7
GEN
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
Valve lapper
90890-04101
This tool is used for lapping the valves.
Ignition checker
90890-06754
YM-34487
This tool is used to check the ignition system components.
Yamaha bond No. 1215
90890-85505
This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
INFO
1 - 8
CHAPTER 2
SPECIFICATIONS
SPEC
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
CHASSIS SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
CONVERSION TABLE
GENERAL TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES.........................................................2-17
CHASSIS TIGHTENING TORQUES.......................................................2-19
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE...................................................................................................2-21
CHASSIS.................................................................................................2-22
..................................................................................2-16
........................................................................2-1
............................................................................2-2
........................................................................2-10
.................................................................2-14
...............................2-16
..............................................................................2-17
....................................2-21
LUBRICATION DIAGRAMS
CABLE ROUTING
.........................................................................................2-25
..........................................................................2-23
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model YBR125
SPEC
Model code
Dimensions
Overall length 1,980 mm (78.0 in)
Overall width 745 mm (29.3 in)
Overall height 1,080 mm (42.5 in)
Seat height 780 mm (30.7 in)
Wheelbase 1,290 mm (50.8 in)
Minimum ground clearance 175 mm (6.89 in)
Minimum turning radius 1,750 mm (68.9 in)
Weight
Wet (with oil and full fuel tank) 120.0 kg (265 lb)
Maximum load (total of cargo, rider, passen-
ger, and accessories)
3D91
200.0 kg (441 lb)
2 - 1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Air-cooled 4-stroke, SOHC ----
3
Displacement 123.7 cm
Cylinder arrangement Forward-inclined single cylinder ---Bore × stroke 54.0 × 54.0 mm (2.13 × 2.13 in) ---Compression ratio 10.0 : 1 ---Standard compression pressure
(at sea level)
Starting system Electric starter and kickstarter ----
Fuel
Recommended fuel Regular unleaded gasoline only ---Fuel tank capacity 12.0 L (2.64 Imp gal, 3.17 US gal) ---Fuel reserve amount 3.0 L (0.66 Imp gal, 0.79 US gal) ----
Engine oil
Type SAE10W30, SAE10W40, SAE15W40,
Recommended engine oil grade API service SE, SF, SG type or higher ---Lubrication system Wet sump ---Engine oil quantity
Total amount 1.20 L (1.06 Imp qt, 1.27 US qt) ---Periodic oil change 1.00 L (0.88 Imp qt, 1.06 US qt) ----
Oil filter type Wire mesh ----
Oil pump
Oil pump type Trochoid ---Inner-rotor-to-outer-rotor-tip-clearance
Outer-rotor-to-oil-pump-housing
clearance
Oil pump-housing-to-inner-rotor-and-
outer-rotor clearance
Spark plug
Model/manufacturer CR6HSA/NGK ---Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) ----
Cylinder head
Volume 15.20 ~ 15.60 cm
Maximum warpage ---- 0.05 mm
1,200 kPa (12.0 kgf/cm
SAE20W40 or SAE20W50
0.07 mm (0.0028 in) 0.15 mm
0.13 ~ 0.19 mm (0.0051 ~ 0.0075 in) 0.26 mm
0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) 0.17 mm
(7.55 cu.in) ----
2
, 170.7 psi) ----
(0.0059 in)
(0.010 in)
(0.0067 in)
3
(0.93 ~ 0.95 cu.in) ----
(0.0020 in)
----
2 - 2
ENGINE SPECIFICATIONS
Item Standard Limit
Camshaft
Drive system Chain drive (left) ---Intake camshaft lobe dimensions
A
B
Measurement A 25.881 ~ 25.981 mm (1.0189 ~ 1.0229 in) 25.851 mm
Measurement B 21.194 ~ 21.294 mm (0.8344 ~ 0.8383 in) 21.164 mm
Exhaust camshaft lobe dimensions
SPEC
(1.0178 in)
(0.8332 in)
A
B
Measurement A 25.841 ~ 25.941 mm (1.0174 ~ 1.0213 in) 25.811 mm
(1.0162 in)
Measurement B 20.997 ~ 21.097 mm (0.8267 ~ 0.8306 in) 20.967 mm
(0.8255 in)
Maximum camshaft runout ---- 0.03 mm
(0.0012 in)
Timing chain
Model/number of links 92RH2005-90M/90 ---Tensioning system Automatic ----
Rocker arm/rocker arm shaft
Rocker arm inside diameter 10.000 ~ 10.015 mm (0.3937 ~ 0.3943 in) 10.030 mm
(0.3949 in)
Rocker arm shaft outside diameter 9.981 ~ 9.991 mm (0.3930 ~ 0.3933 in) 9.950 mm
(0.3917 in)
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.034 mm (0.0003 ~ 0.0013 in) 0.080 mm
(0.003 in)
2 - 3
ENGINE SPECIFICATIONS
Item Standard Limit
Valves, valve seats, valve guides
Valve clearance (cold)
Intake 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) ---Exhaust 0.10 ~ 0.14 mm (0.0039 ~ 0.0055 in) ----
Valve dimensions
SPEC
B
A
Head Diameter Face Width Seat Width Margin Thickness
Valve head diameter A
Intake 25.90 ~ 26.10 mm (1.0197 ~ 1.0276 in) ---Exhaust 21.90 ~ 22.10 mm (0.8622 ~ 0.8701 in) ----
Valve face width B
Intake 1.100 ~ 3.000 mm (0.0433 ~ 0.1181 in) ---Exhaust 1.700 ~ 2.800 mm (0.0669 ~ 0.1102 in) ----
Valve seat width C
Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) ---Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) ----
Valve margin thickness D
Intake 0.40 ~ 0.80 mm (0.0157 ~ 0.0315 in) ---Exhaust 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) ----
Valve stem diameter
Intake 4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in) 4.945 mm
Exhaust 4.960 ~ 4.975 mm (0.1953 ~ 0.1959 in) 4.930 mm
Valve guide inside diameter
Intake 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in) 5.050 mm
Exhaust 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in) 5.050 mm
Valve-stem-to-valve-guide clearance
Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm
Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm
C
(0.1945 in)
(0.1941 in)
(0.1988 in)
(0.1988 in)
(0.0032 in)
(0.0039 in)
D
2 - 4
ENGINE SPECIFICATIONS
Item Standard Limit
Valve stem runout ---- 0.010 mm
Valve seat width (cylinder head side)
Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm
Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm
Valve springs
Free length
Intake 47.06 mm (1.85 in) 44.71 mm
Exhaust 47.06 mm (1.85 in) 44.71 mm
Installed length (valve closed)
Intake 25.6 mm (1.01 in) ---Exhaust 25.6 mm (1.01 in) ----
Spring rate
Intake (K1) 8.01 N/mm (0.82 kg/mm, 45.74 ft · lb) ---Exhaust (K1) 8.01 N/mm (0.82 kg/mm, 45.74 ft · lb) ---Intake (K2) 9.33 N/mm (0.95 kg/mm, 53.27 ft · lb) ---Exhaust (K2) 9.33 N/mm (0.95 kg/mm, 53.27 ft · lb) ----
Compressed spring force (installed)
Intake 160.0 ~ 184.0 N
(16.32 ~ 18.76 kg, 35.97 ~ 41.36 lb)
Exhaust 160.0 ~ 184.0 N
(16.32 ~ 18.76 kg, 35.97 ~ 41.36 lb)
Spring tilt
SPEC
(0.0004 in)
(0.06 in)
(0.06 in)
(1.76 in)
(1.76 in)
----
----
Intake ---- 2.5°/2.1 mm
(2.5°/0.08 in)
Exhaust ---- 2.5°/2.1 mm
(2.5°/0.08 in)
Winding direction (top view)
Intake Clockwise ---Exhaust Clockwise ----
2 - 5
ENGINE SPECIFICATIONS
Item Standard Limit
Cylinder
Bore 54.024 ~ 54.056 mm (2.1269 ~ 2.1282 in) 54.156 mm
Measuring point 40 mm (1.57 in) ----
Piston
Piston-to-cylinder clearance 0.019 ~ 0.035 mm (0.0007 ~ 0.0014 in) 0.15 mm
Diameter D 53.997 ~ 54.029 mm (2.1259 ~ 2.1271 in) ----
H
D
SPEC
(2.1321 in)
(0.0059 in)
Height H 4.8 mm (0.19 in) ---Piston pin bore (in the piston)
Diameter 15.002 ~ 15.013 mm (0.5906 ~ 0.5911 in) 15.043 mm
(0.5922 in)
Offset 0.50 mm (0.0197 in) ---Offset direction Intake side ----
Piston pin
Outside diameter 14.991 ~ 15.000 mm (0.5902 ~ 0.5906 in) 14.971 mm
(0.5894 in)
Piston-pin-to-piston-pin-bore clearance
Piston rings
Top ring
T
Ring type Barrel ---Dimensions (B × T) 1.00 × 2.10 mm (0.039 × 0.082 in) ---End gap (installed) 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.55 mm
Ring side clearance 0.035 ~ 0.070 mm (0.0014 ~ 0.0028 in) 0.120 mm
0.002 ~ 0.022 mm (0.0001 ~ 0.0009 in) 0.072 mm
(0.0028 in)
B
(0.022 in)
(0.0047 in)
2 - 6
ENGINE SPECIFICATIONS
Item Standard Limit
2nd ring
B
T
Ring type Taper ---Dimensions (B × T) 1.00 × 2.10 mm (0.039 × 0.082 in) ---End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.80 mm
Ring side clearance 0.020 ~ 0.060 mm (0.0008 ~ 0.0024 in) 0.120 mm
Oil ring
B
T
Dimensions (B × T) 2.00 × 2.25 mm (0.079 × 0.089 in) ---End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ----
Crankshaft
SPEC
(0.031 in)
(0.0047 in)
C
Width A 46.95 ~ 47.00 mm (1.848 ~ 1.850 in) ---Maximum runout C ---- 0.030 mm
Big end side clearance D 0.150 ~ 0.450 mm (0.0059 ~ 0.0177 in) ---Big end radial clearance E 0.010 ~ 0.021 mm (0.0004 ~ 0.0008 in) ----
Balancer
Balancer drive method Gear ----
Clutch
Clutch type Wet, multiple-disc ---Clutch release method Inner push, cam push ---Clutch cable free play
(at the pivot bolt of the clutch lever)
Friction plate thickness 3.00 mm (0.118 in) 2.80 mm
Plate quantity 4 pcs ---Clutch plate thickness 1.60 mm (0.06 in) ---Plate quantity 3 pcs ---Maximum warpage ---- 0.20 mm
C
E
D
A
(0.0012 in)
10 ~ 15 mm (0.39 ~ 0.59 in) ----
(0.110 in)
(0.0079 in)
2 - 7
ENGINE SPECIFICATIONS
Item Standard Limit
Clutch spring
Free length 29.30 mm (1.15 in) 27.84 mm
Spring quantity 4 pcs ----
Long clutch push rod bending ---- 0.500 mm
Transmission
Transmission type Constant mesh 5-speed ---Primary reduction system Helical gear ---Primary reduction ratio 68/20 (3.400) ---Secondary reduction system Chain drive ---Secondary reduction ratio 45/14 (3.214) ---Operation Left foot operation ---Gear ratio
1st 37/14 (2.643) ---2nd 32/18 (1.778) ---3rd 25/19 (1.316) ---4th 23/22 (1.045) ---5th 21/24 (0.875)
Main axle runout limit ---- 0.03 mm
Drive axle runout limit ---- 0.03 mm
Shifting mechanism
Shift mechanism type Shift drum and guide bar ---Shift fork thickness 4.76 ~ 4.89 mm (0.1874 ~ 0.1925 in) ----
Kickstarter
Kickstarter type Kick and mesh ---Kickstarter pinion gear clip friction
force
Air filter
Air filter element Dry element ----
8 ~ 12 N
(0.82 ~ 1.22 kgf, 1.80 ~ 2.70 lb)
SPEC
(1.10 in)
(0.0197 in)
(0.0012 in)
(0.0012 in)
----
2 - 8
ENGINE SPECIFICATIONS
Item Standard Limit
Carburetor
Type/quantity VM22SH/1 ---Manufacturer MIKUNI ---ID mark 3D91 00 ---Main jet #97.5 ---Main air jet ø0.9 ----
Jet needle 5EJ7-2 ---Needle jet N-7M ---Pilot air jet 1 #60
Pilot air jet 2 ø1.3
Pilot outlet ø1.0 ----
Pilot jet #15 ---Pilot screw turns out 1-1/2 ---Valve seat size ø1.8 ----
Starter jet 1 #25 ---Starter jet 2 ø0.5
Throttle cable free play
(at the flange of the throttle grip)
Fuel level
(below the float chamber mating surface)
Idling condition
Engine idling speed
Air induction system ON 1,400 ~ 1,500 r/min ----
Air induction system OFF 1,350 ~ 1,450 r/min ---CO% (air induction system OFF) 3.0 ~ 4.0% ---Intake vacuum 26.8 ~ 32.2 kPa
Oil temperature 75 ~ 85 °C (167 ~ 185 °F) ----
3 ~ 7 mm (0.12 ~ 0.28 in) ----
6.0 ~ 7.0 mm (0.24 ~ 0.28 in) ----
(201.5 ~ 242.1 mmHg, 7.93 ~ 9.53 inHg)
SPEC
----
2 - 9
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Diamond ---Caster angle 26.33° ----
Trail 90.0 mm (3.54 in) ----
Front wheel
Wheel type Cast wheel ---Rim
Size J18 × 1.60 ----
Material Aluminum ---Wheel travel 110.0 mm (4.33 in) ---Wheel runout
Maximum radial wheel runout ---- 1.0 mm
(0.04 in)
Maximum lateral wheel runout ---- 0.5 mm
(0.02 in)
Rear wheel
Wheel type Cast wheel ---Rim
Size J18 × 1.85 ----
Material Aluminum ---Wheel travel 105.0 mm (4.13 in) ---Wheel runout
Maximum radial wheel runout ---- 1.0 mm
(0.04 in)
Maximum lateral wheel runout ---- 0.5 mm
(0.02 in)
Front tire
Tire type With tube ---Size 2.75-18 42P ---Manufacturer/model CHENG SHIN/SAKURA S-901
PIRELLI/CITY DEMON
Tire pressure (cold tire)
0 ~ 90 kg (0 ~ 198 lb) 175 kPa (1.75 kgf/cm
90 kg ~ Maximum load
(198 lb ~ Maximum load)
Minimum tire tread depth ---- 1.6 mm
175 kPa (1.75 kgf/cm
2
, 25 psi) ----
2
, 25 psi) ----
(0.06 in)
----
----
2 - 10
CHASSIS SPECIFICATIONS
Item Standard Limit
Rear tire
Tire type With tube ---Size 90/90-18 57P ---Manufacturer/model CHENG SHIN/SAKURA S-180
PIRELLI/CITY DEMON
Tire pressure (cold tire)
0 ~ 90 kg (0 ~ 198 lb) 200 kPa (2.00 kgf/cm
90 kg ~ Maximum load
(198 lb ~ Maximum load)
Minimum tire tread depth ---- 1.6 mm
Front brake
Brake type Single-disc brake ---Operation Right-hand operation ---Front disc brake
Diameter × thickness 245.0 × 4.0 mm (9.65 × 0.16 in) ----
Minimum thickness ---- 3.5 mm
Maximum deflection ---- 0.15 mm
Brake pad lining thickness-inner 6.0 mm (0.24 in) 0.8 mm
Brake pad lining thickness-outer 6.0 mm (0.24 in) 0.8 mm
Master cylinder inside diameter 12.70 mm (0.50 in) ---Caliper cylinder inside diameter 35.03 mm (1.3791 in) ---Recommended fluid DOT 3 or 4 ----
Rear brake
Brake type Drum brake ---Operation Right-foot operation ---Brake pedal position 13.5 mm (0.53 in) ---Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) ----
Rear brake drum
Drum brake type Leading, trailing ---Drum inside diameter 130.0 mm (5.12 in) 131.0 mm
Lining thickness 4.0 mm (0.16 in) 2.0 mm
Shoe spring free length 50.5 mm (1.99 in) ----
280 kPa (2.80 kgf/cm
2
, 29 psi) ----
2
, 41 psi) ----
SPEC
----
----
(0.06 in)
(0.14 in)
(0.0059 in)
(0.03 in)
(0.03 in)
(5.16 in)
(0.08 in)
2 - 11
CHASSIS SPECIFICATIONS
Item Standard Limit
Steering
Steering bearing type Ball and race bearing ---Lock-to-lock angle (left) 47° ----
Lock-to-lock angle (right) 47° ----
No./size of steel balls
Upper 16 pcs 0.250 in ----
Lower 16 pcs 0.250 in ----
Front suspension
Suspension type Telescopic fork ---Front fork type Coil spring/oil damper ---Front fork travel 120.0 mm (4.72 in) ---Spring
Free length 337.0 mm (13.27 in) 330.3 mm
Installed length 318.9 mm (12.56 in) ----
Spring rate (K1) 7.37 N/mm (0.75 kgf/mm, 42.08 lb/in) ----
Spring rate (K2) 10.78 N/mm (1.1 kgf/mm, 61.55 lb/in) ----
Spring stroke (K1) 0 ~ 75 mm (0 ~ 2.95 in) ----
Spring stroke (K2) 75 ~ 120 mm (2.95 ~ 4.72 in) ---Optional spring available No ---Fork oil
Recommended oil Fork oil 10W or equivalent ----
Quantity (each front fork leg) 0.154 L (0.136 Imp qt, 0.163 US qt) ----
Level (from the top of the inner
tube, with the inner tube fully com-
pressed, and without the fork
spring)
Inner tube outer diameter 30 mm (1.18 in) ----
Inner tube bend limit ---- 0.2 mm
Rear suspension
Suspension type Swingarm ---Spring/shock absorber type Coil spring/oil damper ---Rear shock absorber assembly travel 90.0 mm (3.54 in) ---Spring
Free length 226.5 mm (8.92 in) 222.0 mm
Installed length 219.5 mm (8.64 in) ----
Spring rate (K1) 13.30 N/mm (1.36 kgf/mm, 75.94 lb/in) ----
Spring rate (K2) 16.20 N/mm (1.65 kgf/mm, 92.50 lb/in) ----
Spring rate (K3) 24.30 N/mm (2.48 kgf/mm, 138.75 lb/in) ----
Spring stroke (K1) 0 ~ 7 mm (0 ~ 0.28 in) ----
Spring stroke (K2) 7 ~ 47 mm (0.28 ~ 1.85 in) ----
Spring stroke (K3) 47 ~ 90 mm (1.85 ~ 3.54 in) ---Optional spring available No ----
166 mm (6.54 in) ----
SPEC
(13.00 in)
(0.008 in)
(8.74 in)
2 - 12
CHASSIS SPECIFICATIONS
Item Standard Limit
Swingarm
Free play limit (at the end of the swingarm)-radial
Free play limit (at the end of the swingarm)-axial
Drive chain
Type/manufacturer DID428V2/DAIDO ---Link quantity 118 ---Drive chain slack 20 ~ 30 mm (0.79 ~ 1.18 in) ---15-Link length limit ---- 191.5 mm
---- 1.0 mm
---- 1.0 mm
SPEC
(0.04 in)
(0.04 in)
(7.54 in)
2 - 13
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage
Ignition system
Ignition system type DC. C.D.I. ---Ignition timing (B.T.D.C.) 7.0° at 1,400 r/min ---Advanced type Digital ----
DC.C.D.I.
Pickup coil resistance/color 248 ~ 372 Ω at 20 °C (68 °F)/white–red ----
C.D.I. unit model/manufacturer 3D9-00/SHY ----
Ignition coil
Model/manufacturer 5VL/SHY ---Minimum ignition spark gap 6.0 mm (0.24 in) ---Primary coil resistance 0.32 ~ 0.48 Ω at 20 °C (68 °F) ---Secondary coil resistance 5.68 ~ 8.52 kΩ at 20 °C (68 °F) ----
Spark plug cap
Material Resin ---Resistance 4.0 ~ 6.0 kΩ at 20 °C (68 °F) ----
Charging system
Type A.C. magneto ---Model/manufacturer 3D9/SHY ---Standard output 14 V 115 W at 5,000 r/min ---Charging coil resistance/color 0.64 ~ 0.96 Ω at 20 °C (68 °F)/white–white ----
Rectifier/regulator
Regulator type Semi conductor-short circuit ---Model/manufacturer SANXIN ---No load regulated voltage (DC) 13.7 ~ 14.7 V ---Rectifier capacity 8.0 A ---Withstand voltage 200 V ----
Battery
Model/manufacturer CB5L-B/TIANJIN TONG YEE INDUS-
Battery voltage/capacity 12 V/5.0 Ah ---Specific gravity 1.280 ----
Headlight
Bulb type Krypton bulb ----
Bulbs (voltage/wattage × quantity)
Headlight 12 V 35 W/35 W × 1 ---Auxiliary light 12 V 5 W × 1 ---Tail/brake light 12 V 5 W/21 W × 1 ---Front turn signal light 12 V 10 W × 2 ---Rear turn signal light 12 V 10 W × 2 ---Meter lighting 12 V 1.7 W × 4 ----
12 V ----
TRIAL
----
2 - 14
Loading...