YAMAHA YFM700RV SERVICE MANUAL

YFM700RV

SERVICE MANUAL

1S3-28197-E0

EBS00000

YFM700RV

SERVICE MANUAL

©2005 by Yamaha Motor Co., Ltd.

First edition, May 2005

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

EBS00002

NOTICE

This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle
repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe
and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all 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.

EBS00003

IMPORTANT INFORMATION

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

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

EBS00004

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa­nied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6

. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.

12

GEN

SPEC

INFO

34

CHK

ENG

ADJ

56

COOL

78

FI

EBS00006

SYMBOLS

The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.

General information

1

Specifications

2

Periodic checks and adjustments

3

Engine

4

Cooling system

5

Fuel injection system

6

Chassis

7

Electrical

8

Troubleshooting

9

CHAS

90

ELEC

–+

TRBL
SHTG

AB

CD

T

.

R

.

EFG

HIJ

LS

G

M

M

E

KLM

B

Symbols 0 to G indicate the following.

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 (Ω, V, A)

G

Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.

Apply engine oil

H

Apply gear oil

I

Apply molybdenum disulfide oil

J

Apply wheel bearing grease

K

Apply lithium-soap-based grease

L

Apply molybdenum disulfide grease

M

NO

LT

New

Symbols N to O in the exploded diagrams
indicate where to apply a locking agent N and
when to install a new part O.

®

Apply the locking agent (LOCTITE

N

Replace

O

)

EBS00008

–+

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND
ADJUSTMENTS

ENGINE

COOLING SYSTEM

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

1

2

3

4

5

FUEL INJECTION SYSTEM

CHASSIS

ELECTRICAL

TROUBLESHOOTING

FI

CHAS

ELEC

TRBL
SHTG

6

7

8

9

CHAPTER 1

GENERAL INFORMATION

GEN

INFO

VEHICLE IDENTIFICATION

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

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

FEATURES

OUTLINE OF THE FI SYSTEM.................................................................1-2

FI SYSTEM................................................................................................ 1-3

SELF-ADJUSTING PARKING BRAKE MECHANISM...............................1-4

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-7

REPLACEMENT PARTS...........................................................................1-7

GASKETS, OIL SEALS AND O-RINGS .................................................... 1-7

LOCK WASHERS/PLATES AND COTTER PINS .....................................1-8

BEARINGS AND OIL SEALS ....................................................................1-8

CIRCLIPS ..................................................................................................1-8

CHECKING THE CONNECTIONS............................................................1-9

SPECIAL TOOLS

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

..........................................................................................1-10

............................................................................1-1

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

1

VEHICLE IDENTIFICATION

EBS00009

GENERAL INFORMATION

VEHICLE IDENTIFICATION

EBS00010

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is
stamped into the left side of the frame.

EBS00011

1

MODEL LABEL

The model label 1 is affixed to the air filter
case cover. This information will be needed to
order spare parts.

GEN

INFO

1 - 1

GEN

FEATURES

EAS20170

FEATURES

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 with 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 air-fuel 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.

INFO

Engine trouble warning light

1

Ignition coil

2

Fuel tank

3
4

Fuel hose

5

Fuel pump

6

Intake air pressure sensor

7

Lean angle sensor

8

Battery

9

Intake air temperature sensor

12

345 6 78

D

EFGH

C

ECU (electronic control unit)

0
A

Air filter case

B

Relay unit (fuel pump relay)

C

Speed sensor

D

Throttle position sensor

E

Crankshaft position sensor

F

Fuel injector

G

Coolant temperature sensor

H

Spark plug

9

0A B

1 - 2

GEN

FEATURES

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/cm
ingly, 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, intake air tem­perature sensor, coolant temperature sensor and speed sensor enable the ECU to determine 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.

INFO

2

, 46.1 psi). Accord-

0

Fuel pump

1

Fuel injector

2

Ignition coil

3

ECU (electronic control unit)

4

Coolant temperature sensor

5

Crankshaft position sensor

6

Intake air pressure sensor

7

Throttle body

8

1

9

É

A

7

È

8

2

Ê

4

B

3

5

6

Intake air temperature sensor

9

Air filter case

0

Throttle position sensor

A

Speed sensor

B

Fuel system

È

Air system

É

Control system

Ê

1 - 3

GEN

FEATURES

SELF-ADJUSTING PARKING BRAKE MECHANISM

Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary
to adjust the adjusting bolt 5 to achieve the proper clearance between the brake caliper piston 7
and the adjusting bolt 5.
This adjustment procedure is unnecessary for vehicles equipped with a self-adjusting parking brake
mechanism. The proper clearance is automatically maintained at all times, ensuring stable braking
performance when parking the vehicle.

INFO

1

2

Parking brake arm

1

Parking brake shaft

2

Adjusting bolt

3

Adjusting bolt sleeve

4

4567

Adjusting bolt

5

Nut

6

Brake caliper piston

7

3

1 - 4

Parking Brake Operation

FEATURES

GEN

INFO

1

2

3

456

1 Parking brake arm
2 Parking brake shaft
3 Adjusting bolt

When the parking brake is operated, the parking brake cable turns the parking brake arm 1. The
rotation of the parking brake arm is changed to axial thrust in the parking brake shaft 2 and the
adjusting bolt 3 is pushed against the adjusting bolt sleeve 4.
When the adjusting bolt sleeve receives the force, the dark shaded area in the above illustration is
pushed and the brake pad 6 is pushed against the brake disc.
When the brake pad wears, the clearance between the brake caliper piston 5 and the brake pad
becomes larger and the force applied to the brake pad becomes weaker.
If this occurs, the self-adjusting parking brake mechanism adjusts automatically to achieve the
proper clearance.

4 Adjusting bolt sleeve
5 Brake caliper piston
6 Brake pad

1 - 5

Parking Brake Operation

FEATURES

GEN

INFO

12

È

É

4

3

Ê

1 Brake caliper piston
2 Nut

When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the
brake caliper piston 1 and the nut 2 are pushed.
When there is proper clearance between the brake caliper piston and the brake pad, no other parts
move because the movement of the brake caliper piston and the nut is absorbed by the backlash of
the threads of the nut and the adjusting bolt 3.
When the movement of the nut is greater than the backlash between the nut and the adjusting bolt,
the parking brake adjusts automatically.
The amount of the adjustment varies with brake fluid pressure. Operating the parking brake makes
no adjustment.
The adjustment operation is as follows.

1. When the brake pedal is operated, the brake fluid pressure increases and the brake caliper pis­ton and the nut move.

2. When the movement of the brake caliper piston and the nut is greater than the backlash of the
threads of the nut and the adjusting bolt, the force È will be required to pull the adjusting bolt.
The force to pull the adjusting bolt will be turned into the rotation torque É by the shape of the
threads of the nut and the adjusting bolt.

3. At this time, the clutch torque Ê between the adjusting bolt and the adjusting bolt sleeve 4 will
decrease depending on the force required to pull the adjusting bolt.
When the rotation torque exceeds the clutch torque, the adjusting bolt rotates and the clearance
between the brake caliper piston and the brake pad decreases by the movement of the threads of
the nut and the adjusting bolt.

3 Adjusting bolt
4 Adjusting bolt sleeve

1 - 6

IMPORTANT INFORMATION

EBS00013

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND
DISASSEMBLY

1. Before removal and disassembly remove all
dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.

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

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

EBS00014

REPLACEMENT PARTS

1. 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.

EBS00015

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 - 7

IMPORTANT INFORMATION

EBS00016

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.

EBS00017

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

EBS00018

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 - 8

IMPORTANT INFORMATION

EBS00019

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

Analog pocket tester

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 - 9

GEN

SPECIAL TOOLS

EBS00021

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN

P/N. YM-, YU-, YS-, YK-, ACC-

Except for US and CDN

P/N. 90890-

Tool No. Tool name/Function Illustration

Slide hammer bolt
Slide hammer bolt (6 mm)

90890-01083

YU-01083-1

This tool is used to remove the rocker arm
shaft.

INFO

90890-01084

YU-01083-3

90890-01135

YU-01135-B

90890-01268

YU-01268

90890-01274

YU-90058
YU-90059

Weight

This tool is used to remove the rocker arm
shaft.

Crankcase separating tool
Crankcase separator

This tool is used to separate the crank­case.

Ring nut wrench
Spanner wrench

This tool is used to loosen or tighten the
rear shock absorber locknuts.

Crankshaft installer pot
Installer pot
Pot installer

90890-01275

YU-90060

This tool is used to install the crankshaft.

Crankshaft installer bolt
Bolt

This tool is used to install the crankshaft.

1 - 10

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Adapter (M16)
Adapter #13

90890-04130

YM-04059

This tool is used to install the crankshaft.

Spacer (crankshaft installer)
Pot spacer

90890-04081

YM-91044

This tool is used to install the crankshaft.

Piston pin puller set
Piston pin puller

90890-01304

YU-01304

This tool is used to remove the piston pin.

INFO

90890-01311

YM-08035-A

90890-01325
YU-24460-01

90890-01352

YU-33984

90890-01327

YM-01327

Tappet adjusting tool
Valve adjuster (3 mm & 4 mm)

This tool is necessary for adjusting the
valve clearance.

Radiator cap tester
Radiator pressure tester

This tool is used to check the cooling sys­tem.

Radiator cap tester adapter
Radiator pressure tester adapter

This tool is used to check the cooling sys­tem.

Damper rod holder (30 mm)

This tool is needed to loosen and tighten
the steering stem bearing retainer.

90890-01404

YM-01404

Flywheel puller

This tool is used to remove the A.C.mag­neto rotor.

1 - 11

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Steering nut wrench
Spanner wrench

90890-01443

YU-33975

90890-01474

YM-01474

90890-01480

YM-01480

This tool is needed to loosen and tighten
the front shock absorber and rear shock
absorber locknuts.

Ball joint remover

This tool is used to remove or install the
ball joints.

Ball joint remover attachment set
Ball joint adapter set

These tools are used to remove or install
the ball joints.

INFO

90890-01498

YM-37134

90890-01701

YS-01880-A

90890-03079

YM-34483

90890-03081

YU-33223

Rear axle nut wrench (46 mm)
Axle nut wrench (46 mm)

This tool is needed to loosen or tighten the
rear axle nut.

Sheave holder
Primary clutch holder

This tool is used to hold the A.C. magneto
rotor when loosen or tighten the A.C. mag­neto rotor nut.

Thickness gauge
Narrow gauge set

This tool is used to measure the valve
clearance.

Compression gauge
Engine compression tester

This tool is used to measure engine com­pression.

90890-04082

Extension

This tool is used to measure engine com­pression.

1 - 12

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Pocket tester
Analog pocket tester

90890-03112

YU-03112-C

This instrument is needed for checking the
electrical system.

Timing light
Inductive clamp timing light

90890-03141

YU-03141

This tool is necessary for checking ignition
timing.

Pressure gauge

90890-03153

YU-03153

This tool is used to measure fuel pressure.

INFO

90890-03176

YM-03176

90890-03174

YU-A1927

90890-03182

YU-03182

90890-04019

YM-04019

Fuel pressure adapter

This tool is used to measure fuel pressure.

Digital circuit tester
Model 88 Multimeter with tachometer

This tool is used to check the electrical
system.

FI diagnostic tool

This tool is used to check the diagnosis.

Valve spring compressor

This tool is needed to remove and install
the valve assemblies.

90890-01243

YM-01253-1

Valve spring compressor attachment
Valve spring compressor adapter (26 mm)

This tool is needed to remove and install
the valve assemblies.

1 - 13

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Middle driven shaft bearing driver
Bearing driver (40 mm)

90890-04058

YM-04058

This tool is used to install the water pump
seal.

Mechanical seal installer
Water pump seal installer

90890-04132

YM-33221-A

This tool is used to install the water pump
seal.

Valve guide remover (ø6)
Valve guide remover (6.0 mm)

90890-04064

YM-4064-A

This tool is needed to remove and install
the valve guides.

INFO

90890-04065

YM-4065-A

90890-04066

YM-04066

90890-04086

YM-91042

90890-06754

YM-34487

Valve guide installer (ø6)
Valve guide installer (6.0 mm)

This tool is needed to install the valve
guides.

Valve guide reamer (ø6)
Valve guide reamer (6.0 mm)

This tool is needed to rebore the new
valve guides.

Universal clutch holder

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

Ignition checker
Opama pet-4000 spark checker

This tool is used to check the ignition sys­tem components.

90890-06760

YU-39951-B

Digital tachometer

This tool is needed to observe engine rpm.

1 - 14

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Yamaha bond No. 1215
(Three bond No. 1215)

90890-85505

This bond is used on crankcase mating
surfaces, etc.

INFO

1 - 15

CHAPTER 2

SPECIFICATIONS

SPEC

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

CHASSIS SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES ........................................................2-16

CHASSIS TIGHTENING TORQUES ......................................................2-19

HOW TO USE THE CONVERSION TABLE

GENERAL TIGHTENING TORQUE SPECIFICATIONS

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE...................................................................................................2-23

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

............................................................................2-4

........................................................................2-12

.................................................................2-14

..............................................................................2-16

..................................................2-22

...............................2-22

....................................2-23

COOLANT FLOW DIAGRAMS

OIL FLOW DIAGRAMS

CABLE ROUTING

.................................................................................2-28

.........................................................................................2-33

.....................................................................2-24

GENERAL SPECIFICATIONS

EBS01001

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code

Dimensions

Overall length 1,845 mm (72.6 in)
Overall width 1,170 mm (46.1 in)
Overall height 1,130 mm (44.5 in)
Seat height 815 mm (32.1 in)
Wheelbase 1,280 mm (50.4 in)
Minimum ground clearance 240 mm (9.45 in)
Minimum turning radius 3,500 mm (137.8 in)

Basic weight

With oil and full fuel tank 192 kg (423 lb)

Engine

Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 686 cm
Bore × stroke 102.0 × 84.0 mm (4.02 × 3.31 in)
Compression ratio 9.20:1
Standard compression pressure (at sea level) 450 kPa (4.5 kg/cm
Starting system Electric starter

Lubrication system
Oil type or grade

Engine oil

For CDN

0° 10° 30° 50° 70° 90° 110°

130°F

1S31 (For Oceania)
1S32 (For CDN)
1S33 (For Europe)

3

(41.86 cu in)

2

, 64.0 psi)

Dry sump

API service SE, SF, SG type or higher

SPEC

YAMALUBE4 (20W40) or SAE 20W40

YAMALUBE4 (10W30) or SAE 10W30

SAE 5W30

-20° -10° 0° 10° 20° 30° 40°

For Europe, Oceania

50°C

2 - 1

GENERAL SPECIFICATIONS

Item Standard

Oil capacity

Engine oil

Periodic oil change 1.75 L (1.54 Imp qt, 1.85 US qt)
With oil filter replacement 1.85 L (1.63 Imp qt, 1.96 US qt)
Total amount 2.30 L (2.02 Imp qt, 2.43 US qt)

Radiator capacity (including all routes)
Air filter
Fuel

Type Regular unleaded gasoline only (For CDN,

Fuel tank capacity 11.0 L (2.42 Imp gal, 2.91 US gal)
Fuel reserve amount 2.6 L (0.57 Imp gal, 0.69 US gal)

Fuel injector

Type/quantity 297500-0390/1
Manufacturer DENSO

Spark plug

Type/manufacturer CR8E/NGK
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

Clutch type
Transmission

Primary reduction system Spur gear
Primary reduction ratio 77/34 (2.265)
Secondary reduction system Chain drive
Secondary reduction ratio 38/14 (2.714)
Transmission type Constant mesh, 5-speed/forward, 1 speed/

Operation Left foot operation
Gear ratio

1st gear 38/13 (2.923)
2nd gear 28/14 (2.000)
3rd gear 25/17 (1.471)
4th gear 25/22 (1.136)
5th gear 22/24 (0.917)
Reverse gear 24/13 × 29/12 (4.462)

Chassis

Frame type Aluminum die-cast and steel tube frame
Caster angle 5°
Camber angle –1.0°
Kingpin angle 14.8°
Kingpin offset 2.8 mm (0.11 in)
Trail 21.0 mm (0.83 in)
Tread front (STD) 940 mm (37.01 in)
Tread rear (STD) 900 mm (35.43 in)
Toe-in (with tires touching the ground) 2 ~ 12 mm (0.08 ~ 0.47 in)

1.61 L (1.42 Imp qt, 1.70 US qt)
Wet type element

Europe)
Unleaded gasoline only (For Oceania)

Wet, multiple disc

reverse

SPEC

2 - 2

GENERAL SPECIFICATIONS

Item Standard

Tire

Type Tubeless
Size front AT21 × 7-10

rear AT20 × 10-9

Manufacturer front DUNLOP

rear DUNLOP

Type front KT341 Radial

rear KT345 Radial

Tire pressure (cold tire)

Maximum load* 100 kg (220 lb)
Off-road riding front 27.5 kPa (0.28 kg/cm

rear 27.5 kPa (0.28 kg/cm
*Load is total weight of cargo, rider and
accessories

Brake

Front brake type Dual disc brake

operation Right hand operation
Rear brake type Single disc brake

operation Right foot operation

Suspension

Front suspension Double wishbone
Rear suspension Swingarm (link suspension)

Shock absorber

Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas-oil damper

Wheel travel

Front wheel travel 230 mm (9.06 in)
Rear wheel travel 256 mm (10.08 in)

Electrical system

Ignition system Transistorized coil ignition (digital)
Generator system A.C. magneto
Battery type GT9B-4
Battery capacity 12 V 8.0 Ah

Bulb type
Bulb voltage/wattage × quantity

Headlight 12 V 30 W/30 W × 2
Tail/brake light LED
Indicator light

Neutral indicator light LED
Fuel level warning light LED
Reverse indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED

Krypton bulb

2

2

SPEC

, 4.0 psi)
, 4.0 psi)

2 - 3

ENGINE SPECIFICATIONS

EBS01002

SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Cylinder head

Maximum warpage ---- 0.03 mm

(0.0012 in)

Cylinder

Bore 102.000 ~ 102.010 mm (4.0157 ~ 4.0161 in) 102.080 mm

(4.0189 in)

Measuring point 50.0 mm (1.97 in) ----

Out of round 0.05 mm

(0.002 in)

Camshaft

Drive system Chain drive (left) ---­Camshaft lobe dimensions

A

B

Intake measurement “A” 43.300 ~ 43.400 mm (1.7047 ~ 1.7087 in) 43.200 mm

(1.7008 in)

“B” 37.026 ~ 37.126 mm (1.4577 ~ 1.4617 in) 36.926 mm

(1.4538 in)

Exhaust measurement “A” 43.129 ~ 43.229 mm (1.6980 ~ 1.7019 in) 43.029 mm

(1.6941 in)

“B” 37.057 ~ 37.157 mm (1.4589 ~ 1.4629 in) 36.957 mm

(1.4550 in)

Maximum camshaft runout ---- 0.03 mm

(0.0012 in)

Timing chain

Model/number of links 98XRH2010/126 ---­Tensioning system Automatic ----

2 - 4

ENGINE SPECIFICATIONS

Item Standard Limit

Rocker arm/rocker arm shaft

Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) ---­Shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) ---­Arm-to-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) ----

Valve, valve seat, valve guide

Valve clearance–intake (cold) 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in) ---­Valve clearance–exhaust (cold) 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ---­Valve dimensions

SPEC

B

A

Head Diameter Face Width Seat Width Margin Thickness

Valve head diameter “A”

Intake 37.9 ~ 38.1 mm (1.4921 ~ 1.5000 in) ---­Exhaust 31.9 ~ 32.1 mm (1.2559 ~ 1.2638 in) ----

Valve face width “B”

Intake 2.26 mm (0.0890 in) ---­Exhaust 2.26 mm (0.0890 in) ----

Valve seat width “C”

Intake 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm

Exhaust 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm

Valve margin thickness “D”

Intake 0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in) ---­Exhaust 0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in) ----

Valve stem diameter

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

Exhaust 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 5.930 mm

Valve guide inside diameter

Intake 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.050 mm

Exhaust 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.050 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

(0.063 in)

(0.063 in)

(0.2341 in)

(0.2335 in)

(0.2382 in)

(0.2382 in)

(0.0031 in)

(0.0039 in)

D

2 - 5

ENGINE SPECIFICATIONS

Item Standard Limit

Valve stem runout ---- 0.01 mm

Valve seat width

Intake 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm

Exhaust 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm

Valve spring

Free length

Intake 38.79 mm (1.53 in) 36.85 mm

Exhaust 38.79 mm (1.53 in) 36.85 mm

Installed length (valve closed)

Intake 35.00 mm (1.38 in) ---­Exhaust 35.00 mm (1.38 in) ----

Compressed spring force (installed)

Intake 169.0 ~ 199.0 N

(17.23 ~ 20.29 kg, 37.99 ~ 44.73 lb)

Exhaust 169.0 ~ 199.0 N

(17.23 ~ 20.29 kg, 37.99 ~ 44.73 lb)

Spring tilt

SPEC

(0.0004 in)

(0.0630 in)

(0.0630 in)

(1.45 in)

(1.45 in)

----

----

Intake ---- 2.5°/1.70 mm

(2.5°/0.067 in)

Exhaust ---- 2.5°/1.70 mm

(2.5°/0.067 in)

Winding direction (top view)

Intake Clockwise ---­Exhaust Clockwise ----

2 - 6

ENGINE SPECIFICATIONS

Item Standard Limit

Piston

Piston-to-cylinder clearance 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm

Diameter “D” 101.955 ~ 101.970 mm

(4.0140 ~ 4.0146 in)

H

D

Height “H” 10 mm (0.39 in) ---­Offset 0.5 mm (0.0197 in) ---­Offset direction Intake side ---­Piston pin bore inside diameter 23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in) 23.045 mm

Piston pin outside diameter 22.991 ~ 23.000 mm (0.9052 ~ 0.9055 in) 22.971 mm

Piston-pin-to-piston-pin-bore clear­ance

Piston rings

Top ring

0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in) 0.074 mm

SPEC

(0.0051 in)

----

(0.9073 in)

(0.9044 in)

(0.0029 in)

B

T

Ring type Barrel ---­Dimensions (B × T) 1.20 × 3.80 mm (0.05 × 0.15 in) ---­End gap (installed) 0.20 ~ 0.35 mm (0.008 ~ 0.014 in) 0.60 mm

(0.024 in)

Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) 0.12 mm

(0.0047 in)

2nd ring

B

T

Ring type Taper ---­Dimensions (B × T) 1.20 × 4.00 mm (0.05 × 0.16 in) ---­End gap (installed) 0.35 ~ 0.50 mm (0.014 ~ 0.020 in) 0.85 mm

(0.033 in)

Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) 0.13 mm

(0.0051 in)

2 - 7