Yamaha YFM25RSE2Y, YFM25RSEY, YFM25RY user guide

2009

SERVICE MANUAL

YFM25RY

YFM25RSEY

YFM25RSE2Y

4D3-28197-11LIT-11616-22-09

EAS20040

YFM25RY/YFM25RSEY/YFM25RSE2Y

SERVICE MANUAL

Corporation, U.S.A.

First edition, April 2008

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-11616-22-09

EAS20071

IMPORTANT

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possib le to include all the kno wledge of a mechan ic 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 f or an y se rvice information changes that apply to this model. This policy is intended to provide the customer with the most satisf action 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.

TIP

• 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.

EAS20081

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided,

WARNING

could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid

damage to the vehicle or other property.

A TIP 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 f or the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

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

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

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

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

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

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

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

EAS20100

SYMBOLS

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

TIP

The following symbols are not relevant to every vehicle.

No SYMBOL DEFINITION

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

No SYMBOL DEFINITION

10 Gear oil

11 Molybdenum-disulfide oil

12 Brake fluid

13 Wheel-bearing grease

14 Lithium-soap-based grease

15 Molybdenum-disulfide grease

16 Silicone grease

17 Apply locking agent (LOCTITE®)

18 Replace the part

New

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHASSIS

ENGINE

1 2 3 4 5

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

6 7 8

GENERAL INFORMATION

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

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

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

IMPORTANT INFORMATION.......................................................................1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-2

REPLACEMENT PARTS.........................................................................1-2

GASKETS, OIL SEALS AND O-RINGS..................................................1-3

LOCK WASHERS/PLATES AND COTTER PINS...................................1-3

BEARINGS AND OIL SEALS.................................................................1-3

CIRCLIPS ...............................................................................................1-3

CHECKING THE CONNECTIONS ...............................................................1-4

SPECIAL TOOLS..........................................................................................1-5

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

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

EAS20150

MODEL LABEL

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

IDENTIFICATION

1-1

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 1-5.

3. When disassembling, always keep mated

parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

IMPORTANT INFORMATION

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.

1-2

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.

IMPORTANT INFORMATION

ECA13300

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

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.

EAS20230

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manufacturer’s mar ks 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.

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.

1-3

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 sev eral times.

CHECKING THE CONNECTIONS

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

TIP

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform steps (1) to (3).

• As a quick remedy, use a contact revitalizer available at most part stores.

3. Check:

• All connections Loose connection → Connect properly.

TIP

If the pin “1” on the terminal is flattened, bend it up.

4. Connect:

• Lead

• Coupler

• Connector

TIP

Make sure all connections are tight.

5. Check:

• Continuity (with the pocket tester)

1-4

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 ma y differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.

TIP

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

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

Tool name/Tool No. Illustration

Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1

Weight 90890-01084 YU-01083-3

Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B

Reference

pages

5-7

5-58

Ring nut wrench 90890-01268 Spanner wrench YU-01268

3-24

1-5

SPECIAL TOOLS

Tool name/Tool No. Illustration

Crankshaft installer pot 90890-01274 Installing pot YU-90058

Crankshaft installer bolt 90890-01275 Bolt YU-90060

Adapter (M10) 90890-01383 Adapter #2 YU-90062

Reference

pages

5-60

Spacer 90890-01288

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

5-60

5-25

1-6

SPECIAL TOOLS

Tool name/Tool No. Illustration

Tappet adjusting tool 90890-01311 Six piece tappet set YM-A5970

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

Bolt (M8 × 80 mm) 90890-01359

Reference

pages

3-5

5-46

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

Thickness gauge 90890-03180 Feeler gauge set YU-26900-9

Compression gauge 90890-03081 Engine compression tester YU-33223

5-46, 5-47

3-4, 5-33

3-9

1-7

SPECIAL TOOLS

Tool name/Tool No. Illustration

Extension 90890-04082

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

Timing light 90890-03141 Inductive clamp timing light YU-03141

Valve spring compressor 90890-04019 YM-04019

Reference

pages

3-9

1-4, 5-51, 7-31, 7-32, 7-33, 737, 7-38, 7-39, 7-40, 7-41, 7-42

3-8

5-17, 5-22

Valve spring compressor attachment 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1

Universal clutch holder 90890-04086 YM-91042

Valve guide remover (ø6) 90890-04064 Valve guide remover (6.0 mm) YM-04064-A

5-17, 5-22

5-32, 5-34

5-19

1-8

SPECIAL TOOLS

Tool name/Tool No. Illustration

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

Valve lapper 90890-04101 Valve lapping tool YM-A8998

PTT wrench 46 90890-06588 Axle nut wrench (46 mm) YM-37134

Reference

pages

5-19

5-20

4-13, 4-14

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

Digital tachometer 90890-06760 YU-39951-B

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

7-39

3-5, 3-8

5-55

1-9

SPECIFICATIONS

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

ENGINE SPECIFICATIONS..........................................................................2-4

CHASSIS SPECIFICATIONS......................................................................2-10

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

TIGHTENING TORQUES............................................................................2-14

GENERAL TIGHTENING TORQUE SPECIFICATIONS.......................2-14

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

CHASSIS TIGHTENING TORQUES....................................................2-17

LUBRICATION POINTS AND LUBRICANT TYPES..................................2-19

ENGINE................................................................................................2-19

LUBRICATION SYSTEM CHART AND DIAGRAMS .................................2-21

ENGINE OIL LUBRICATION CHART...................................................2-21

LUBRICATION DIAGRAMS..................................................................2-23

CABLE ROUTING ......................................................................................2-29

GENERAL SPECIFICATIONS

EAS29110

GENERAL SPECIFICATIONS

Model

Model 4D3D/4D3H/4D3M

Dimensions

Overall length 1625 mm (64.0 in) Overall width 1070 mm (42.1 in) Overall height 1040 mm (40.9 in) Seat height 730 mm (28.7 in) Wheelbase 1110 mm (43.7 in) Ground clearance 100 mm (3.9 in) Minimum turning radius 2900 mm (114 in)

Weight

With oil and fuel 150.0 kg (331 lb)

Engine

Engine type Air cooled 4-stroke, SOHC Cylinder arrangement Forward-inclined single cylinder Displacement 249.0 cm Bore × stroke 74.0 × 58.0 mm (2.91 × 2.28 in) Compression ratio 9.50 : 1 Standard compression pressure (at sea level) 1100 kPa/720 r/min (11.0 kgf/cm

156.5 psi/720 r/min) Starting system Electric starter Lubrication system Wet sump

Engine oil

Type YAMALUBE 4 (10W-40) or SAE 10W-40,

YAMALUBE 4 (20W-50) or SAE 20W-50

Recommended engine oil grade API service SG type or higher, JASO standard

Engine oil quantity

Without oil filter element replacement 1.25 L (1.32 US qt, 1.10 Imp.qt) With oil filter element replacement 1.35 L (1.43 US qt, 1.19 Imp.qt) Total amount 1.60 L (1.69 US qt, 1.41 Imp.qt)

Oil filter

Oil filter type Paper

Air filter

Air filter element Wet element Air filter oil grade Foam air filter oil or equivalent oil

Fuel

Recommended fuel Unleaded gasoline only Fuel tank capacity 9.0 L (2.38 US gal, 1.98 Imp.gal) Fuel reserve amount 1.0 L (0.26 US gal, 0.22 Imp.gal)

Carburetor

Type × quantity BSR29 × 1 Manufacturer MIKUNI

/720 r/min,

2-1

GENERAL SPECIFICATIONS

Spark plug (s)

Manufacturer/model NGK/DR7EA Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Clutch type Wet, multiple-disc

Transmission

Primary reduction system Spur gear Primary reduction ratio 76/22 (3.455) Secondary reduction system Chain drive Secondary reduction ratio 38/14 (2.714) Transmission type Constant mesh 5-speed Operation Left foot operation 1st 37/13 (2.846) 2nd 33/18 (1.833) 3rd 29/21 (1.381) 4th 27/24 (1.125) 5th 28/29 (0.966)

Chassis

Frame type Steel tube frame Caster angle 6 ° Camber angle -1.5 ° Kingpin angle 14.8 ° Trail 23.0 mm (0.91 in) Tread rear (STD) 824.0 mm (32.44 in) Tread front (STD) 826.0 mm (32.52 in) Toe-in (with tire touching the ground) 9.0–19.0 mm (0.35–0.75 in)

Front tire

Type Tubeless Size AT20 × 7-10 Manufacturer/model DUNLOP/KT201

Rear tire

Type Tubeless Size AT19 × 10-9 Manufacturer/model DUNLOP/KT205A

Tire air pressure (measured on cold tires)

Maximum loading limit 100.0 kg (220 lb) Off-road riding

Front 27.5 kPa (0.28 kgf/cm Rear 27.5 kPa (0.28 kgf/cm

Front brake

Type Dual disc brake Operation Right hand operation

Rear brake

Type Single disc brake Operation Right foot operation

Front suspension

Type Double wishbone Spring/shock absorber type Coil spring/oil damper (4D3D)

Coil spring/gas-oil damper (4D3H, 4D3M)

Wheel travel 190 mm (7.5 in)

, 4.0 psi)

2-2

GENERAL SPECIFICATIONS

Rear suspension

Type Swingarm Spring/shock absorber type Coil spring/gas-oil damper Wheel travel 200 mm (7.9 in)

Electrical system

Ignition system DC. CDI Charging system AC magneto Model YTZ7S Voltage, capacity 12 V, 6.0 Ah

Headlight

Bulb type Krypton bulb Bulb voltage, wattage × quantity

Headlight 12 V, 30.0/30.0 W × 2 Tail/brake light 12 V, 5.0/21.0 W × 1 (4D3D)

12 V, 0.5/3.9 W × 1 (4D3H, 4D3M)

Neutral indicator light 12 V, 1.7 W × 1

2-3

EAS29120

ENGINE SPECIFICATIONS

Cylinder head

Volume 20.50–21.50 cm

(1.25–1.31 cu.in)

Warpage limit 0.05 mm (0.0020 in)

Cylinder

Bore 74.000–74.016 mm (2.9134–2.9140 in) Wear limit 74.100 mm (2.9173 in)

Camshaft

Drive system Chain drive (right) Camshaft lobe dimensions

Intake A 36.890–36.990 mm (1.4524–1.4563 in) Limit 36.790 mm (1.4484 in) Intake B 30.111–30.211 mm (1.1855–1.1894 in) Limit 30.011 mm (1.1815 in) Exhaust A 36.891–36.991 mm (1.4524–1.4563 in) Limit 36.791 mm (1.4485 in) Exhaust B 30.092–30.192 mm (1.1847–1.1887 in) Limit 29.992 mm (1.1808 in)

Camshaft runout limit 0.030 mm (0.0012 in)

Timing chain

Model/number of links DID SCR-0404 SV/104 Tensioning system Automatic

Rocker arm/rocker arm shaft

Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) Limit 12.036 mm (0.4739 in) Rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in) Limit 11.950 mm (0.4705 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.037 mm (0.0004–0.0015 in)

2-4

ENGINE SPECIFICATIONS

Valve, valve seat, valve guide

Valve clearance (cold)

Intake 0.05–0.10 mm (0.0020–0.0039 in) Exhaust 0.10–0.15 mm (0.0039–0.0059 in)

Valve dimensions

Valve head diameter A (intake) 33.90–34.10 mm (1.3346–1.3425 in) Valve head diameter A (exhaust) 28.40–28.60 mm (1.1181–1.1260 in)

Valve face width B (intake) 2.26 mm (0.0890 in) Valve face width B (exhaust) 2.26 mm (0.0890 in)

Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.60 mm (0.06 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.60 mm (0.06 in)

Valve margin thickness D (intake) 0.80–1.20 mm (0.0315–0.0472 in) Valve margin thickness D (exhaust) 0.80–1.20 mm (0.0315–0.0472 in)

Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in) Limit 5.945 mm (0.234 in) Valve stem diameter (exhaust) 5.960–5.975 mm (0.2346–0.2352 in) Limit 5.930 mm (0.233 in) Valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in) Limit 6.050 mm (0.238 in) Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in) Limit 6.050 mm (0.238 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.003 in) Valve-stem-to-valve-guide clearance

(exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.004 in) Valve stem runout limit 0.01 mm (0.0004 in) Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.60 mm (0.06 in) Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.60 mm (0.06 in)

2-5

ENGINE SPECIFICATIONS

V alve spring

Inner spring

Free length (intake) 36.17 mm (1.42 in) Limit 34.36 mm (1.35 in) Free length (exhaust) 36.17 mm (1.42 in) Limit 34.36 mm (1.35 in) Installed length (intake) 30.50 mm (1.20 in) Installed length (exhaust) 30.50 mm (1.20 in) Spring rate K1 (intake) 14.70 N/mm (1.50 kgf/mm, 83.94 lbf/in) Spring rate K2 (intake) 19.00 N/mm (1.94 kgf/mm, 108.49 lbf/in) Spring rate K1 (exhaust) 14.70 N/mm (1.50 kgf/mm, 83.94 lbf/in) Spring rate K2 (exhaust) 19.00 N/mm (1.94 kgf/mm, 108.49 lbf/in) Installed compression spring force (intake) 75.00–91.70 N (7.65–9.35 kgf, 16.86–20.61

lbf)

Installed compression spring force (exhaust) 75.00–91.70 N (7.65–9.35 kgf, 16.86–20.61 Spring tilt (intake) 2.5 °/1.60 mm (2.5 °/0.063 in)

Spring tilt (exhaust) 2.5 °/1.60 mm (2.5 °/0.063 in)

lbf)

Winding direction (intake) Counterclockwise Winding direction (exhaust) Counterclockwise

Outer spring

Free length (intake) 36.63 mm (1.44 in) Limit 34.80 mm (1.37 in) Free length (exhaust) 36.63 mm (1.44 in) Limit 34.80 mm (1.37 in) Installed length (intake) 32.00 mm (1.26 in) Installed length (exhaust) 32.00 mm (1.26 in) Spring rate K1 (intake) 30.90 N/mm (3.15 kgf/mm, 176.44 lbf/in) Spring rate K2 (intake) 40.80 N/mm (4.16 kgf/mm, 232.97 lbf/in) Spring rate K1 (exhaust) 30.90 N/mm (3.15 kgf/mm, 176.44 lbf/in) Spring rate K2 (exhaust) 40.80 N/mm (4.16 kgf/mm, 232.97 lbf/in) Installed compression spring force (intake) 128.50–157.90 N (13.10–16.10 kgf, 28.89–

35.50 lbf)

Installed compression spring force (exhaust) 128.50–157.90 N (13.10–16.10 kgf, 28.89–

35.50 lbf)

Spring tilt (intake) 2.5 °/1.60 mm (2.5 °/0.063 in) Spring tilt (exhaust) 2.5 °/1.60 mm (2.5 °/0.063 in)

Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise

2-6

ENGINE SPECIFICATIONS

Piston

Piston-to-cylinder clearance 0.010–0.025 mm (0.0004–0.0010 in) Limit 0.15 mm (0.0059 in) Diameter D 73.983–73.998 mm (2.9127–2.9133 in) Height H 5.0 mm (0.20 in)

Offset 0.25 mm (0.0098 in) Offset direction Intake side Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Limit 17.043 mm (0.6710 in) Piston pin outside diameter 16.991–17.000 mm (0.6689–0.6693 in) Limit 16.971 mm (0.6681 in) Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in) Limit 0.072 mm (0.0028 in)

Piston ring

Top ring

Ring type Barrel Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in)

End gap (installed) 0.19–0.31 mm (0.007–0.012 in) Limit 0.56 mm (0.022 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in)

2nd ring

Ring type Taper Dimensions (B × T) 0.80 × 2.80 mm (0.03 × 0.11 in)

End gap (installed) 0.30–0.45 mm (0.012–0.018 in) Limit 0.80 mm (0.032 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.115 mm (0.0045 in)

Oil ring

Dimensions (B × T) 1.50 × 2.60 mm (0.06 × 0.10 in)

End gap (installed) 0.10–0.35 mm (0.004–0.014 in)

2-7

ENGINE SPECIFICATIONS

Crankshaft

Width A 69.25–69.30 mm (2.726–2.728 in) Runout limit C 0.03 mm (0.0012 in) Big end side clearance D 0.350–0.650 mm (0.0138–0.0256 in) Limit 0.50 mm (0.0197 in) Big end radial clearance E 0.010–0.025 mm (0.0004–0.0010 in)

Balancer

Balancer drive method Gear

Clutch

Friction plate thickness 2.90–3.10 mm (0.114–0.122 in) Limit 2.80 mm (0.110 in) Plate quantity 6 pcs Clutch plate thickness 1.50–1.70 mm (0.059–0.067 in) Plate quantity 5 pcs Clutch plate warpage limit 0.20 mm (0.0079 in) Clutch spring free length 47.80 mm (1.88 in) Limit 46.50 mm (1.83 in) Spring quantity 5 pcs Clutch release method Inner push, cam push Push rod 2 bending limit 0.10 mm (0.004 in)

Transmission

Main axle runout limit 0.06 mm (0.0024 in) Drive axle runout limit 0.06 mm (0.0024 in) Main axle assembly width 102.2–102.4 mm (4.02–4.03 in)

Shifting mechanism

Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.05 mm (0.002 in)

2-8

ENGINE SPECIFICATIONS

Carburetor

ID mark 4D31 00 Main jet #133.8 Main air jet #140 Jet needle 5DH66-1 Needle jet P-0M (922) Pilot air jet 1 #85 Pilot air jet 2 #170 Pilot outlet 0.9 Pilot jet #25 Bypass 1 0.8 Bypass 2 0.8 Bypass 3 0.8 Valve seat size 2 Starter jet 1 #55 Starter jet 2 0.5 Throttle valve size #100 Float height 13.0 mm (0.51 in)

Idling condition

Engine idling speed 1500–1600 r/min CO% 4.0–5.0% Intake vacuum 34.0 kPa (255 mmHg, 10.0 inHg) Oil temperature 55.0–65.0 °C (131.0–149.0 °F)

Oil pump

Oil pump type Trochoid Inner-rotor-to-outer-rotor-tip clearance 0.15 mm (0.0059 in) Limit 0.23 mm (0.0091 in) Outer-rotor-to-oil-pump-housing clearance 0.100–0.151 mm (0.0039–0.0059 in) Limit 0.22 mm (0.0087 in) Oil-pump-housing-to-inner-and-outer-rotor

clearance 0.04–0.09 mm (0.0016–0.0035 in) Limit 0.16 mm (0.0063 in) Oil pressure (hot) 3.0 kPa/1550 r/min (0.03 kgf/cm

0.4 psi/1550 r/min) Pressure check location Cylinder head

/1550 r/min,

2-9

CHASSIS SPECIFICATIONS

EAS29130

CHASSIS SPECIFICATIONS

Front suspension

Shock absorber travel 90.7 mm (3.57 in) (4D3D)

88.4 mm (3.48 in) (4D3H, 4D3M) Spring free length 248.5 mm (9.78 in) (4D3D)

Spring rate K1 23.00 N/mm (2.35 kgf/mm, 131.33 lbf/in) Spring stroke K1 0.0–90.7 mm (0.00–3.57 in) (4D3D)

Optional spring available No

Rear suspension

Rear shock absorber assembly travel 87.0 mm (3.43 in) Spring free length 240.5 mm (9.47 in) Installed length 230.0 mm (9.06 in) (4D3D)

Spring rate K1 54.00 N/mm (5.51 kgf/mm, 308.34 lbf/in) Spring stroke K1 0.0–87.0 mm (0.00–3.43 in) Optional spring available No Enclosed gas/air pressure (STD) 2500 kPa (25.0 kgf/cm

Rear axle

Rear axle runout limit 1.5 mm (0.06 in)

Swingarm

Swingarm end free play limit (radial) 1.0 mm (0.04 in) Swingarm end free play limit (axial) 1.0 mm (0.04 in)

Front wheel

Wheel type Panel wheel Rim size 10 × 5.5AT Rim material Aluminum Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in)

Rear wheel

Wheel type Panel wheel Rim size 9 × 8.5AT Rim material Aluminum Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in)

Drive chain

Type/manufacturer 520V/DAIDO Link quantity 91 Drive chain slack 45.0–55.0 mm (1.77–2.17 in) 15-link length limit 239.3 mm (9.42 in)

224.6 mm (8.84 in) (4D3H, 4D3M)

0.0–88.4 mm (0.00–3.48 in) (4D3H, 4D3M)

228.0 mm (8.98 in) (4D3H, 4D3M)

, 355.6 psi) (4D3D)

1150–1250 kPa (11.5–12.5 kgf/cm

1813 psi) (4D3H, 4D3M)

, 166.8–

2-10

CHASSIS SPECIFICATIONS

Front brake

Type Dual disc brake Disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) Brake disc thickness limit 3.0 mm (0.12 in) Brake disc deflection limit 0.15 mm (0.006 in) Brake pad lining thickness (inner) 4.4 mm (0.17 in) Limit 1.5 mm (0.06 in) Brake pad lining thickness (outer) 4.4 mm (0.17 in) Limit 1.5 mm (0.06 in) Master cylinder inside diameter 12.7 mm (0.50 in) Caliper cylinder inside diameter 27.00 mm (1.06 in) Recommended fluid DOT 4

Rear brake

Type Single disc brake Disc outside diameter × thickness 200.0 × 4.0 mm (7.87 × 0.16 in) Brake disc thickness limit 3.5 mm (0.14 in) Brake disc deflection limit 0.15 mm (0.006 in) Brake pad lining thickness (inner) 4.2 mm (0.17 in) Limit 1.0 mm (0.04 in) Brake pad lining thickness (outer) 4.2 mm (0.17 in) Limit 1.0 mm (0.04 in) Master cylinder inside diameter 12.7 mm (0.50 in) Caliper cylinder inside diameter 33.96 mm (1.34 in) Recommended fluid DOT 4

Lever and pedal

Brake lever free play 0 mm (0 in) Brake pedal height 40.0 mm (1.57 in) Parking brake cable and length 64.0–68.0 mm (2.52–2.68 in) Clutch cable free play (lever end) 5.0–10.0 mm (0.20–0.39 in) Throttle cable free play 2.0–4.0 mm (0.08–0.16 in) Speed limiter length Less than 12 mm (0.47 in) Shift pedal height 15.2 mm (0.60 in)

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