Chapter 7, APPENDICES

Chapter 7, APPENDICES xjcdadmin Tue, 06/08/2010 - 01:09

Maintenance Specifications -- Chassis

Maintenance Specifications -- Chassis xjcdadmin Tue, 06/08/2010 - 01:10

Chassis

 

Steering System: 

Steering Bearing Type

 

Taper Roller Bearing

Front Suspension: 

(Each) Front Fork Travel 

Fork Spring Free Length 
< Limit > 

Spring Rate/Stroke

Optional Spring Oil Capacity 

Oil Grade

Enclosed Air Pressure: 

Standard 

Minimum- Maximum

 

150 mm (5.9 in)

511 mm (20.1 in)
< 505 mm (19.9 in) >

K, = 3.92 N/mm (0.40 kg/mm, 22.4 lb/in)

0- 100 mm (0- 3.94 in) K2 = 4.90 N/mm (0.50 kg/mm, 28 lb/in)

100- 150 mm (3.94- 5.90 in) No.

389 cm3 (13.7 Imp oz, 13.2 US oz) YAMAHA Fork & Shock Oil 10wt or equivalent fork oil

39.2 kPa (0.4 kg/cm2, 5.7 psi)

Zero- 118 kPa

(Zero - 1.2 kg/cm2, Zero - 17.1 psi)

Rear Suspension: (Each) 

Shock Absorber Travel 

Spring Free Length 

Spring Fitting Length 

Spring Rate/Stroke

 

70 mm (2.76 in)

243.5 mm (9.59 in)

217.5 mm (8.56 in)

K, = 21.6 N/mm (2.2 kg/mm, 123.2 lb/in)
0- 44 mm (0- 1.73 in) 
K2 = 28.4 N/mm (2.9 kg/mm, 162.3 lb/in)
44- 70 mm (1.73- 2.76 in)

Rear Arm: 

Swingarm Free Play Limit: 
End

Side

 

1.0 mm (0.04 in) 
1.0 mm (0.04 in)

Wheel: 

Front Wheel Type 

Rear Wheel Type 

Front Rim Size/Material 

Rear Rim Size/Material Rim 

Runout Limit: 
Vertical
Lateral

 

Cast Wheel 

Cast Wheel

MT2.15x 19/Aluminum 

MT3.00x 16/Aluminum 

2.0 mm (0.08 in) 
2.0 mm (0.08 in)

Disc Brake: 
Type Front 

Outside Dia. x Thickness

Dual disc

267 x 5 mm (10.5 x 0.2 in)

Pad Thickness:

Inner 
<Limit>* 

Outer 
<Limit>*

5.5 mm (0.22 in) 
0.5 mm (0.02 in) 

5.5 mm (0.22 in) 
0.5 mm (0.02 in)

Master Cylinder Inside Dia. 

Caliper Cylinder Inside Dia. 

Brake Fluid Type

15.87 mm (0.62 in) 

38.18 mm (1.50 in) 

DOT #3

Drum Brake: Type Rear Drum Inside Dia.

<Limit> Lining Thickness

<l_imit> Shoe Spring Free Length

 

Leading trailing

200 mm (7.87 in)

201  mm (7.91 in) 4 mm (0.16 in)

2 mm (0.08 in) 68 mm (2.7 in)

 

Brake Lever & Brake Pedal: 

Brake Lever Free Play 

Brake Pedal Position 

Brake Pedal Free Play

 

2-5mm (0.08 - 0.20 in)/at lever end

10 mm (0.4 in) below the top of the footrest

20-30mm (0.8- 0.12 in)

Clutch Lever Free Play: 2 - 3 mm (0.08 - 0.12 in)/at lever pivot

 

 

Tightening torque

Part to be tightened

Part name

Thread size

Q'ty

Tightening torque

Remarks

Nm

m-kg

fflb

Engine mounting bolt: 
Front Upper
Front Lower

Nut 
Nut

M10 P1.25 M10P1.25


2

 42

 4.2

30

 

Rear

Nut

M12 P1.25

2

90

9.0

65

 

Engine mounting stay

Nut

M8 P1.25

4

33

3.3

24

 

Downtube

Bolt

M8 P1.25

4

33

3.3

24

 

Downtube & Cross pipe

Nut

M8 P1.25

2

33

3.3

24

 

Handle crown & Steering shaft

Nut

M20 P1.0

1

110

11

80

 

Ring nut (Lower)

Nut

M22 P1.0

1

6

0.6

4.3

See page 6-25

Handle crown & Inner tube

Nut

M8 P1.25

2

20

2.0

14

 

Handle crown & Handlebar holder

Bolt

M8 PI.25

4

20

2.0

14

 

Under bracket & Inner tube

Bolt

M8 PI.25

4

23

2.3

17

 

Front wheel axle

Nut castle

M14 P1.5

1

105

10.5

75

 

Front wheel axle pinch bolt

Nut self locking

M8 P1.25

1

20

2.0

14

 

Pivot shaft (Right)

Bolt

M22P1.5

1

5.5

0.55

4.0

Taper roller bearing

Pivot shaft (Left and Right)

Bolt/Nut

M22P1.5

1

100

10.0

72

 

Rear wheel axle

Nut castle

M14P1.5

1

105

10.5

75

 

Rear wheel axle pinch bolt

Bolt

M8 P1.25

1

20

2.0

14

 

Rear shock absorber (Upper).

Nut cap

M8 P1.25

2

20

2.0

14

 

Rear shock absorber (Lower)

L Nut cap R Bolt

M10P1.25

2

30

3.0

22

 

Footrest

Bolt

M8 P1.25

4

29

2.9

21

 

Tension bar & Brake plate

Bolt

M8 P1.25

1

20

2.0

14

 

Tension bar & Rear arm

Bolt

M8 P1.25

1

20

2.0

14

 

Camshaft lever & Camshaft

Bolt

M6 P1.0

1

9

0.9

6.5

 

Disc brake section: Brake disc & Hub (Front)

Bolt

M8 P1.25

12

20

2.0

14

 

Master cylinder & Brake hose (Front)

Bolt union

M10 P1.25

1

26

2.6

19

 

Brake hose & Joint

Bolt union

M10 P1.25

1

26

2.6

19

 

Caliper & Brake hose

Bolt union

M10 P1.25 

2

26

2.6

19

 

Caliper & Front fork (Front)

M10 P1.25

4

35

3.5

25

 

Caliper bleed screw (Ftont)

M8 P1.25

2

6

0.6

4.3

 

Front fender

Bolt

M6 P1.0

4

9

0.9

6.5

 

Final gear & Rear arm

Nut

M10P1.25

4

42

4.2

30

 

Final gear:

Drive shaft

Nut

M14P1.5

1

110

11

80

Oil

Bearing housing

Flange bolt

M8 PI.25

4

25

25

18

 

Bearing housing

Nut

M8 P1.25

6

23

2.3

17

 

Oil filler cap

Plug

M14P1.5

1

23

2.3

17

 

Oil drain screw

Plug

M14P1.5

1

23

2.3

17

 

Bearing retainer

-

M65P1.5

1

110

11

80

Left-hand thread

Cross joint

Hexagon bolt with washer

M8 PI .25

4

44

4.4

32

 

Muffler bracket & Frame

Bolt

M8 PI.25

3

23

2.3

17

 

Rear fender

Bolt

M10P1.25

2

32

3.2

23

 

Muffler bracket & Muffler

Bolt

M10P1.25

2

25

2.5

18

 

 

 

General Torque Specifications

General Torque Specifications xjcdadmin Tue, 06/08/2010 - 01:10

GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasteners with standard l.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a criss-cross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.

 

A (Nut)

B (Bolt)

General torque specifications

Nm

m-kg

ft-lb

10 mm

6 mm

6

0.6

4.3

12 mm

8 mm

15

1.5

11

14 mm

10 mm

30

3.0

22

17 mm

12 mm

55

5.5

40

19 mm

14 mm

85

8.5

61

22 mm

16 mm

130

13.0

94

 

DEFINITION OF UNITS

Unit

Read

Definition

Measure

mm cm

millimeter centimeter

10"3 meter 10-2 meter

Length Length

kg

kilogram

103 gram

Weight

N

Newton

1 kg x m/sec2

Force

Nm 
m-kg

Newton meter 
Meter kilogram

N x m 
m x kg

Torque 
Torque

Pa 

N/mm

Pascal

Newton per millimeter

N/m2

N/mm

Pressure 

Spring rate

cm3

Liter

Cubic centimeter

 

Volume or Capacity

r/min

Rotation per minute

 

Engine Speed