Item | Standard | Limit |
---|---|---|
Model Code | 5LV5 (USA except for California) |   |
  | 5LV6 (CDN) |   |
  | 5LV7 (California) |   |
Dimensions |   |   |
Overall length | 2,125 mm (83.7 in) |   |
Overall width | 765 mm (30.1 in) |   |
Overall height | 1,190 mm (46.9 in) |   |
Seat height | 820 mm (32.3 in) |   |
Wheelbase | 1,450 mm (57.1 in) |   |
Minimum ground clearance | 140 mm (5.5 in) |   |
Minimum turning radius | 2,900 mm (114.2 in) |   |
Weight |   |   |
Wet (with oil and a full fuel tank) | 231 kg (509 lb) |   |
  | 232 kg (512 lb) (for california) |   |
Dry (without oil and fuel) | 208 kg (459 lb) |   |
  | 209 kg (461 lb) (for california) |   |
Maximum load (total of cargo, rider, passenger, and accessories) | 189 kg (417 lb) |   |
  | 188 kg (415 lb) (for california) |   |
Item | Standard | Limit | ||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Engine |   |   | ||||||||||||
Engine type | Liquid-cooled, 4-stroke, DOHC |   | ||||||||||||
Displacement | 998 cm 3 |   | ||||||||||||
Cylinder arrangement | Forward-inclined parallel 4-cylinder |   | ||||||||||||
Bore & stroke | 74 x 58 mm (2.91 x 2.28 in) |   | ||||||||||||
Compression ratio | 11.4 : 1 |   | ||||||||||||
Engine idling speed | 1,050 - 1,150 r/min |   | ||||||||||||
Vacuum pressure at engine idling speed | 30 kPa (225 mmHg, 8.86 in Hg) |   | ||||||||||||
Standard compression pressure (at sea level) | 1,450 kPa (14.5 kg/cm2 , 206 psi) at 400 r/min |   | ||||||||||||
Fuel |   |   | ||||||||||||
Recommended fuel | Unleaded fuel (for USA) |   | ||||||||||||
  | Regular unleaded gasoline (for CDN) |   | ||||||||||||
Fuel tank capacity: |   |   | ||||||||||||
Total (including reserve) | 21 L (18.5 Imp qt, 22.2 US qt) |   | ||||||||||||
Reserve only | 4.0 L (3.52 Imp qt, 4.22 US qt) |   | ||||||||||||
Engine Oil |   |   | ||||||||||||
Lubrication system | Wet sump |   | ||||||||||||
Recommended oil:![]() | Yamalube 4 (20W40) or SAE 20W40 type SE motor oil |   | ||||||||||||
Quantity: |   |   | ||||||||||||
Total amount | 3.7 L (3.2 Imp qt, 3.8 US qt) |   | ||||||||||||
Without oil filter cartridge replacement | 2.8 L (2.4 Imp qt, 2.9 US qt) |   | ||||||||||||
With oil filter cartridge replacement | 3.0 L (2.6 Imp qt, 3.1 US qt) |   | ||||||||||||
Oil pressure (hot) | 45 kPa (0.45 kg/cm2 , 6.40 psi) at 1,100 r/min |   | ||||||||||||
Relief valve opening pressure | 490 - 570 kPa (4.9 - 5.7 kg/cm2 , 69.7 - 81.1 psi) |   | ||||||||||||
Oil filter |   |   | ||||||||||||
Oil filter type | Cartridge (paper) |   | ||||||||||||
Part number | 5GH-13440-00-00 |   | ||||||||||||
Oil Pump |   |   | ||||||||||||
Oil pump type | Trochoidal |   | ||||||||||||
Inner-rotor-to-outer-rotor-tip clearance | 0.09 - 0.15 mm (0.004 - 0.006 in) |   | ||||||||||||
Outer-rotor-to-oil-pump-housing clearance | 0.03 - 0.08 mm (0.001 - 0.003 in) |   | ||||||||||||
Bypass valve opening pressure | 180 - 220 kPa (1.8 - 2.2 kg/cm2 , 25.6 - 31.3 psi) |   | ||||||||||||
Relief valve operating pressure | 490 - 570 kPa (71.1 - 82.7 psi) |   | ||||||||||||
Oil pressure (hot) | 45 kPa @ 1100 rpm (6.5 psi @ 1100 rpm) |   | ||||||||||||
Cooling System |   |   | ||||||||||||
Radiator capacity | 2.4 L (2.11 Imp qt, 2.53 US qt) |   | ||||||||||||
Radiator cap opening pressure | 95 - 125 kPa (0.95 - 1.25 kg/cm2 , 13.1 - 17.8 psi) |   | ||||||||||||
Radiator core |   |   | ||||||||||||
Width | 340 mm (13.4 in) |   | ||||||||||||
Height | 238 mm (9.4 in) |   | ||||||||||||
Depth | 24 mm (0.94 in) |   | ||||||||||||
Coolant reservoir capacity | 0.3 L (0.26 Imp qt, 0.32 US qt) |   | ||||||||||||
Water pump: |   |   | ||||||||||||
Water pump type | Single-suction centrifugal pump |   | ||||||||||||
Reduction ratio | 68/43 x 28/28 (1.581) |   | ||||||||||||
Max. impeller shaft tilt |   | 0.15 mm (0.006 in) | ||||||||||||
Starting system type | Electric starter |   | ||||||||||||
Spark plugs |   |   | ||||||||||||
Model (manufacturer) x quantity | CR9E / U27ESR-N (NGK / DENSO) x 4 |   | ||||||||||||
Spark plug gap | 0.7 - 0.8 mm (0.028 - 0.031 in) |   | ||||||||||||
Cylinder head |   |   | ||||||||||||
Volume | 13.45 - 14.05 cc (0.82 - 0.86 in3) |   | ||||||||||||
Max. warpage:![]() |   | 0.1 mm (0.004 in) | ||||||||||||
Camshafts |   |   | ||||||||||||
Drive system | Chain drive (right) |   | ||||||||||||
Camshaft cap inside diameter | 24.500 - 24.521 mm (0.9646 - 0.9654 in) |   | ||||||||||||
Camshaft journal diameter | 24.459 - 24.472 mm (0.9630 - 0.9635 in) |   | ||||||||||||
Camshaft-journal-to-camshaft-cap clearance | 0.028 - 0.062 mm (0.0011 - 0.0024 in) |   | ||||||||||||
Intake camshaft lobe dimensions:![]() |   |   | ||||||||||||
Measurement A | 32.5 - 32.6 mm (1.2795 - 1.2835 in) | 32.4 mm (1.2756 in) | ||||||||||||
Measurement B | 24.95 - 25.05 mm (0.9823 - 0.9862 in) | 24.85 mm (0.9783 in) | ||||||||||||
Measurement C | 7.45 - 7.65 mm (0.2933 - 0.3012 in) |   | ||||||||||||
Exhaust camshaft lobe dimensions:![]() |   |   | ||||||||||||
Measurement A | 32.95 - 33.05 mm (1.2972 - 1.3012 in) | 32.85 mm (1.2933 in) | ||||||||||||
Measurement B | 24.95 - 25.05 mm (0.9823 - 0.9862 in) | 24.85 mm (0.9783 in) | ||||||||||||
Measurement C | 7.75 - 7.95 mm (0.3051 - 0.3126 in) |   | ||||||||||||
Max. camshaft runout:![]() |   | 0.03 mm (0.0012 in) | ||||||||||||
Valve Timing |   |   | ||||||||||||
Intake-open (BTDC) | 32° |   | ||||||||||||
Intake-closed (ABDC) | 56° |   | ||||||||||||
Exhaust-open (BBDC) | 61° |   | ||||||||||||
Exhaust-closed (ATDC) | 35° |   | ||||||||||||
Overlap angle | 67° |   | ||||||||||||
Timing chain |   |   | ||||||||||||
Model / number of links | RH2015 / 130 |   | ||||||||||||
Tensioning system | Automatic |   | ||||||||||||
Valves, valve seats, valve guides |   |   | ||||||||||||
Valve clearance (cold) | 0.11 - 0.20 mm (0.0043 - 0.0079 in) |   | ||||||||||||
Intake | 0.21 - 0 25 mm (0 0083 - 0 0098 in) |   | ||||||||||||
Exhaust Valve Dimensions:
|   |   | ||||||||||||
Valve head diameter A: |   |   | ||||||||||||
Intake | 22.9 - 23.1 mm (0.9016 - 0.9094 in) |   | ||||||||||||
Exhaust | 24.4 - 24.6 mm (0.9606 - 0.9685 in) |   | ||||||||||||
Valve face width B: |   |   | ||||||||||||
Intake | 1.76 - 2.90 mm (0.0693 - 0.1142 in) |   | ||||||||||||
Exhaust | 1.76 - 2.90 mm (0.0693 - 0.1142 in) |   | ||||||||||||
Valve seat width C: |   |   | ||||||||||||
Intake | 0.9 - 1.1 mm (0.035 - 0.043 in) |   | ||||||||||||
Exhaust | 0.9 - 1.1 mm (0.035 - 0.043 in) |   | ||||||||||||
Valve margin thickness D: |   |   | ||||||||||||
Intake | 0.5 - 0.9 mm (0.020 - 0.035 in) |   | ||||||||||||
Exhaust | 0.5 - 0.9 mm (0.020 - 0.035 in) |   | ||||||||||||
Valve stem diameter: |   |   | ||||||||||||
Intake | 3.975 - 3.900 mm (0.1565 - 0.1535 in) | 3.945 mm (0.1553 in) | ||||||||||||
Exhaust | 4.465 - 4.480 mm (0.1758 - 0.1764 in) | 4.43 mm (0.1744 in) | ||||||||||||
Valve guide inside diameter: |   |   | ||||||||||||
Intake | 4.000 - 4.012 mm (0.1575 - 0.1580 in) | 4.05 mm (0.1594 in) | ||||||||||||
Exhaust | 4.500 - 4.512 mm (0.1772 - 0.1776 in) | 4.55 mm (0.1791 in) | ||||||||||||
Valve-stem-to-valve-guide clearance: |   |   | ||||||||||||
Intake | 0.010 - 0.037 mm (0.0004 - 0.0015 in) | 0.08 mm (0.0031 in) | ||||||||||||
Exhaust | 0.020 - 0.047 mm (0.0008 - 0.0019 in) | 0.10 mm (0.0039 in) | ||||||||||||
Valve stem runout:![]() |   | 0.01 mm (0.0004 in) | ||||||||||||
Valve seat width: |   |   | ||||||||||||
Intake | 0.9 - 1.1 mm (0.035 - 0.043 in) |   | ||||||||||||
Exhaust | 0.9 - 1.1 mm (0.035 - 0.043 in) |   | ||||||||||||
Valve seat material - intake | PB6 |   | ||||||||||||
Valve seat material - exhaust | PB7W |   | ||||||||||||
Valve springs free length: |   |   | ||||||||||||
Intake | 38.90 mm (1.53 in) |   | ||||||||||||
Exhaust | 40.67 mm (1.60 in) |   | ||||||||||||
Spring rate - intake (K1) | 20.3 N/mm (115.91 lb/in) |   | ||||||||||||
Spring rate - intake (K2) | 26.75 N/mm (152.74 lb/in) |   | ||||||||||||
Spring rate - exhaust (K1) | 20.74 N/mm (118.43 lb/in) |   | ||||||||||||
Spring rate - exhaust (K2) | 27.83 N/mm (158.91 lb/in) |   | ||||||||||||
Installed length (valve closed): |   |   | ||||||||||||
Intake | 34.50 mm (1.36 in) |   | ||||||||||||
Exhaust | 35.00 mm (1.38 in) |   | ||||||||||||
Compressed spring force (installed): |   |   | ||||||||||||
Intake | 82 - 96 N (8.2 - 9.6 kg, 18.4 - 25.4 lb) |   | ||||||||||||
Exhaust | 110 - 126 N (11.0 - 12.6 kg, 24.7 - 28.3 lb) |   | ||||||||||||
Spring tilt:![]() |   |   | ||||||||||||
Intake |   | 2.5° / 1.7 mm (2.5° / 0.067 in) | ||||||||||||
Exhaust |   | 2.5° / 1.8 mm (2.5° / 0.071 in) | ||||||||||||
Winding direction (top view): |   |   | ||||||||||||
Intake | Clockwise |   | ||||||||||||
Exhaust | Clockwise |   | ||||||||||||
Cylinders |   |   | ||||||||||||
Cylinder arrangement | Forward-inclined, parallel 4-cylinder |   | ||||||||||||
Bore & stroke | 74 x 58 mm (2.91 x 2.28 in) |   | ||||||||||||
Compression ratio | 11.4 : 1 |   | ||||||||||||
Bore | 74.00 - 74.01 mm (2.9134 - 2.9138 in) |   | ||||||||||||
Max. taper |   | 0.05 mm (0.0016 in) | ||||||||||||
Max. out-of-round |   | 0.05 mm (0.0016 in) | ||||||||||||
Pistons |   |   | ||||||||||||
Piston part number | 4XV-11631-00 |   | ||||||||||||
Piston-to-cylinder clearance | 0.030 - 0.055 mm (0.001 - 0.002 in) | 0.12 mm (0.005 in) | ||||||||||||
Diameter D:![]() | 73.955 - 73.970 mm (2.9118 - 2.9122 in) |   | ||||||||||||
Height H | 5 mm (0.20 in) |   | ||||||||||||
Piston pin bore (in the piston): |   |   | ||||||||||||
Diameter | 17.002 - 17.013 mm (0.6694 - 0.6698 in) | 17.043 mm (0.6710 in) | ||||||||||||
Offset | 0.5 mm (0.0197 in) |   | ||||||||||||
Offset direction | Intake side |   | ||||||||||||
Piston pins: |   |   | ||||||||||||
Outside diameter | 16.991 - 17.000 mm (0.6689 - 0.6693 in) | 16.971 mm (0.6681 in) | ||||||||||||
Piston-pin-to-piston-pin-bore clearance | 0.002 - 0.022 mm (0.00008 - 0.00087 in) | 0.072 mm (0.0028 in) | ||||||||||||
Piston rings: |   |   | ||||||||||||
top ring -![]() |   |   | ||||||||||||
Ring type | Barrel |   | ||||||||||||
Dimensions (B x T) | 0.90 x 2.75 mm (0.035 x 0.108 in) |   | ||||||||||||
End gap (installed) | 0.32 - 0.44 mm (0.010 - 0.020 in) |   | ||||||||||||
Ring side clearance | 0.030 - 0.065 mm (0.0012 - 0.0026 in) |   | ||||||||||||
Plating/coating | Chrome plated/ferox coating |   | ||||||||||||
2nd ring -![]() |   |   | ||||||||||||
Ring type | Taper |   | ||||||||||||
Dimensions (B x T) | 0.8 x 2.8 mm (0.031 x 0.110 in) |   | ||||||||||||
End gap (installed) | 0.43 - 0.58 mm (0.017 - 0.023 in) |   | ||||||||||||
Ring side clearance | 0.020 - 0.055 mm (0.0008 - 0.0022 in) |   | ||||||||||||
Plating/coating | Parkerrizing |   | ||||||||||||
Oil ring -![]() |   |   | ||||||||||||
Dimensions (B x T) | 1.5 x 2.6 mm (0.059 x 0.101 in) |   | ||||||||||||
End gap (installed) | 0.10 - 0.35 mm (0.004 - 0.014 in) |   | ||||||||||||
Plating/coating | Chrome plated/parkerrizing |   | ||||||||||||
Connecting rods |   |   | ||||||||||||
Crankshaft-pin-to-big-end-bearing clearance | 0.031 - 0.055 mm (0.0012 - 0.0022 in) |   | ||||||||||||
Bearing color code | –1 = Violet 0 = White 1 = Blue 2 = Black |   | ||||||||||||
Connecting rod length | 110.45 - 110.55 mm (4.348 - 4.352 in) |   | ||||||||||||
Crankshaft![]() |   |   | ||||||||||||
Width A | 52.40 - 57.25 mm (2.063 - 2.254 in) |   | ||||||||||||
Width B | 300.75 - 302.65 mm (11.84 - 11.92 in) |   | ||||||||||||
Max. runout C |   | 0.03 mm (0.0012 in) | ||||||||||||
Big end side clearance D | 0.160 - 0.262 mm (0.006 - 0.010 in) |   | ||||||||||||
Crankshaft-journal-to-crankshaft-journal-bearing clearance | 0.029 - 0.053 mm (0.0011 - 0.0021 in) |   | ||||||||||||
Bearing color code | –1 = Pink/violet 0 = Pink/white 1 = Pink/blue 2 = Pink/black 3 = Pink/brown |   | ||||||||||||
Position of thrust bearing | #4 Journal |   | ||||||||||||
Clutch |   |   | ||||||||||||
Clutch type | Wet, multiple disc |   | ||||||||||||
Clutch release method | Cam (pull rod type) |   | ||||||||||||
Clutch release method operation | Cable operation |   | ||||||||||||
Operation | Left-hand operation |   | ||||||||||||
Clutch cable free play (at the end of the clutch lever) | 10 - 15 mm (0.39 - 0.59 in) |   | ||||||||||||
Friction plates: |   |   | ||||||||||||
Thickness | 2.92 - 3.08 mm (0.115 - 0.121 in) | 2.82 mm (0.111 in) | ||||||||||||
Plate quantity | 8 |   | ||||||||||||
Thickness | 3.42 - 3.58 mm (0.135 - 0.141 in) | 3.32 mm (0.131 in) | ||||||||||||
Plate quantity | 1 |   | ||||||||||||
Clutch plates: |   |   | ||||||||||||
Thickness | 1.9 - 2.1 mm (0.075 - 0.083 in) |   | ||||||||||||
Plate quantity | 8 |   | ||||||||||||
Max. warpage |   | 0.1 mm (0.004 in) | ||||||||||||
Clutch springs: |   |   | ||||||||||||
Free length | 50 mm (1.97 in) |   | ||||||||||||
Spring quantity | 6 |   | ||||||||||||
Transmission |   |   | ||||||||||||
Transmission type | Constant mesh, 6-speed |   | ||||||||||||
Primary reduction system | Spur gear |   | ||||||||||||
Primary reduction ratio | 68/43 (1.581) |   | ||||||||||||
Secondary reduction system | Chain drive |   | ||||||||||||
Secondary reduction ratio | 44/16 (2.750) |   | ||||||||||||
Operation | Left-foot operation |   | ||||||||||||
Gear ratios: |   |   | ||||||||||||
1st gear | 35/14 (2.500) |   | ||||||||||||
2nd gear | 35/19 (1.842) |   | ||||||||||||
3rd gear | 30/20 (1.500) |   | ||||||||||||
4th gear | 28/21 (1.333) |   | ||||||||||||
5th gear | 30/25 (1.200) |   | ||||||||||||
6th gear | 29/26 (1.115) |   | ||||||||||||
Max. main axle runout |   | 0.08 mm (0.003 in) | ||||||||||||
Max. drive axle runout |   | 0.08 mm (0.003 in) | ||||||||||||
Shifting mechanism |   |   | ||||||||||||
Shift mechanism type | Guide bar |   | ||||||||||||
Max. shift fork guide bar bending |   | 0.1 mm (0.004 in) | ||||||||||||
Installed shift rod length | 260 mm (10.2 in) |   | ||||||||||||
Air filter type | Dry element |   | ||||||||||||
Fuel pump |   |   | ||||||||||||
Pump type | Electrical |   | ||||||||||||
Model (manufacturer) | 4SV (MITSUBISHI) |   | ||||||||||||
Output pressure | 20 kPa (0.2 kg/cm2, 2.8 psi) |   | ||||||||||||
Carburetors |   |   | ||||||||||||
Model (manufacturer) x quantity | BSR37 (MIKUNI) x 4 |   | ||||||||||||
Throttle cable free play (at the flange of the throttle grip) | 3 - 5 mm (0.12 - 0.20 in) |   | ||||||||||||
ID mark | 5LV5 40 |   | ||||||||||||
Main jet | Carburetors 1 and 4: #132.5 |   | ||||||||||||
  | Carburetors 2 and 3: #130 |   | ||||||||||||
Main air jet | #80 |   | ||||||||||||
Jet needle | Carburetor 1 and 4: 5D129-3/5 |   | ||||||||||||
  | Carburetor 2 and 3: 5D130-3/5 |   | ||||||||||||
Needle jet | P-OM |   | ||||||||||||
Pilot air jet | #85 |   | ||||||||||||
Pilot outlet | 1.0 |   | ||||||||||||
Pilot jet | #15 |   | ||||||||||||
Bypass 1 | 0.9 |   | ||||||||||||
Bypass 2 | 0.9 |   | ||||||||||||
Bypass 3 | 0.9 |   | ||||||||||||
Pilot screw turns out | 2.0 |   | ||||||||||||
Valve seat size | 1.5 |   | ||||||||||||
Starter jet 1 | #42.5 |   | ||||||||||||
Starter jet 2 | 0.8 |   | ||||||||||||
Throttle valve size | #115 |   | ||||||||||||
Fuel level (above the line on the float chamber) | 3.0 - 4.0 mm (0.118 - 0.157 in) |   | ||||||||||||
Idling Condition |   |   | ||||||||||||
Engine idle speed | 1050 - 1150 rpm |   | ||||||||||||
CO% with AIS blocked | 4 - 5% |   | ||||||||||||
Intake vacuum | 225 mm Hg (8.858 in Hg) |   | ||||||||||||
Water temperature | 95 - 105°C |   | ||||||||||||
oil temperature | 85 - 95°C |   | ||||||||||||
Max. EXUP cable free play (at the EXUP valve pulley) | 1.5 mm (0.059 in) |   |
Item | Standard | Limit |
---|---|---|
Frame |   |   |
Frame type | Double cradle |   |
Caster angle | 26° |   |
Trail | 104 mm (4.09 in) |   |
Front wheel |   |   |
Wheel type | Cast wheel |   |
Rim: |   |   |
Size | 17 x MT3.50 |   |
Material | Aluminum |   |
Wheel travel | 140 mm (5.51 in) |   |
Wheel runout: |   |   |
Max. radial wheel runout |   | 1 mm (0.04 in) |
Max. lateral wheel runout |   | 0.5 mm (0.02 in) |
Rear wheel |   |   |
Wheel type | Cast wheel |   |
Rim: |   |   |
Size | 17 x MT5.50 |   |
Material | Aluminum |   |
Wheel travel | 135 mm (5.31 in) |   |
Wheel runout: |   |   |
Max. radial wheel runout |   | 1 mm (0.04 in) |
Max. lateral wheel runout |   | 0.5 mm (0.02 in) |
Front tire |   |   |
Tire type | Tubeless |   |
Size | 120/70 ZR17 (58W) |   |
Model (manufacturer) | MEZ4Y FRONT (METZELER) |   |
  | BT020F U (BRIDGESTONE) |   |
Tire pressure (cold): |   |   |
0 - 90 kg | 250 kPa (2.5 kgf/cm2, 36 psi) |   |
90 - 201 kg | 250 kPa (2.5 kgf/cm2, 36 psi) |   |
High-speed riding | 250 kPa (2.5 kgf/cm2, 36 psi) |   |
Min. tire tread depth |   | 1.0 mm (0.04 in) |
Rear tire |   |   |
Tire type | Tubeless |   |
Size | 180/55 ZR17 (73W) |   |
Model (manufacturer) | MEZ4Y (METZELER) |   |
  | BT020R U (BRIDGESTONE) |   |
Tire pressure (cold): |   |   |
0 - 90 kg | 270 kPa (2.7 kgf/cm2, 39 bar) |   |
90 - 201 kg | 290 kPa (2.9 kgf/cm2, 42 bar) |   |
High-speed riding | 290 kPa (2.9 kgf/cm2, 42 bar) |   |
Min. tire tread depth | 1.0 mm (0.04 in) |   |
Front brakes |   |   |
Brake type | Dual-disc brake |   |
Operation | Right-hand-operation |   |
Brake lever free play | 2.3 - 11.5 mm (0.09 - 0.45 in) |   |
Recommended fluid | DOT 4 |   |
Brake discs: |   |   |
Diameter x thickness | 298 x 5 mm (11.7 x 0.20 in) |   |
Min. thickness |   | 4.5 mm (0.18 in) |
Max. deflection |   | 0.1 mm (0.004 in) |
Brake pad lining thickness:![]() | 5.5 mm (0.22 in) | 0.5 mm (0.02 in) |
Master cylinder inside diameter | 14 mm (0.05 in) |   |
Caliper cylinder inside diameter | 30.2 mm (1.19 in) and 27 mm (1.06 in) |   |
Rear brake |   |   |
Brake type | Single-disc brake |   |
Operation | Right-foot operation |   |
Brake pedal position (from the top of the brake pedal to the top of the rider footrest) | 35 - 40 mm (1.38 - 1.57 in) |   |
Brake pedal free play | 4.0 - 8.5 mm (0.16 - 0.33 in) |   |
Recommended fluid | DOT 4 |   |
Brake discs: |   |   |
Diameter x thickness | 267 x 5 mm (10.51 x 0.20 in) |   |
Min. thickness |   | 4.5 mm (0.18 in) |
Max. deflection |   | 0.1 mm (0.004 in) |
Brake pad lining thickness:![]() | 5.5 mm (0.22 in) | 0.5 mm (0.02 in) |
Master cylinder inside diameter | 12.7 mm (0.5 in) |   |
Caliper cylinder inside diameter | 42.9 mm (1.69 in) |   |
Front suspension |   |   |
Suspension type | Telescopic fork |   |
Front fork type | Coil spring/oil damper |   |
Front fork travel | 140 mm (5.51 in) |   |
Spring: |   |   |
Free length | 344.0 mm (13.5 in) |   |
Spacer length | 66.0 mm (2.60 in) |   |
Installed length | 320.0 mm (12.6 in) |   |
Spring rate (K1) | 7.8 N/mm (0.78 kg/mm, 43.7 lb/in) |   |
Spring rate (K2) | 11.8 N/mm (1.2 kg/mm, 67.2 lb/in) |   |
Spring stroke (K1) | 0 - 64 mm (0 - 2.52 in) |   |
Spring stroke (K2) | 64 - 140 mm (2.52 - 5.51 in) |   |
Optional spring available | No |   |
Fork oil: |   |   |
Recommended oil | Suspension oil “01” or equivalent |   |
Quantity (each front fork leg) | 435 cm 3 (15.3 Imp oz, 14.7 US oz) |   |
Level (from the top of the inner tube, with the inner tube fully compressed, and without the fork spring) | 140 mm (5.51 in) |   |
Spring preload adjusting positions: |   |   |
Minimum | 5 (from fully turned out position) |   |
Standard | 2 |   |
Maximum | 1 |   |
Rebound damping adjusting positions: |   |   |
Minimum | 17 (from fully turned-in position) |   |
Standard | 7 |   |
Maximum | 1 |   |
Compression damping adjusting positions: |   |   |
Minimum | 21 (from fully turned-in position) |   |
Standard | 6 |   |
Maximum | 1 |   |
Steering |   |   |
Steering bearing type | Angular ball bearings |   |
Lock to lock angle (left) | 34° |   |
Lock to lock angle (right) | 34° |   |
Rear suspension |   |   |
Suspension type | Swingarm (link suspension) |   |
Rear shock absorber assembly type | Coil spring/gas-oil damper |   |
Rear shock absorber assembly travel | 65 mm (2.56 in) |   |
Spring: |   |   |
Free length | 182.5 mm (7.19 in) |   |
Installed length | 163 mm (6.42 in) |   |
Spring rate (K1) | 73.6 N/mm (7.5 kg/mm, 420 lb/in) |   |
Spring stroke (K1) | 0 - 65 mm (0 - 2.56 in) |   |
Optional spring available | No |   |
Standard spring preload gas/air pressure | 1,200 kPa (12 kg/cm2, 170.7 psi) |   |
Spring preload adjusting positions: |   |   |
Minimum | 1 (from fully turned-in position) |   |
Standard | 6 |   |
Maximum | 11 |   |
Rebound damping adjusting positions: |   |   |
Minimum | 20 (from fully turned-in position) |   |
Standard | 10 |   |
Maximum | 3 |   |
Compression damping adjusting positions: |   |   |
Minimum | 1 (from fully turned-in position) |   |
Standard | 7 |   |
Maximum | 12 |   |
Swingarm |   |   |
Free play (at the end of the swingarm): |   |   |
Radial |   | 1 mm (0.04 in) |
Axial |   | 1 mm (0.04 in) |
Drive chain |   |   |
Model (manufacturer) | 50ZVM (DAIDO) |   |
Link quantity | 116 |   |
Drive chain slack | 40 - 50 mm (1.57 - 1.97 in) |   |
Maximum ten-link section | 150.1 mm (5.91 in) | 152.5 mm (6.00 in) |
Item | Standard | Limit |
---|---|---|
System voltage | 12 V |   |
Ignition system |   |   |
Ignition system type | Transistorized coil ignition |   |
Ignition timing | 5° BTDC at 1,100 r/min |   |
Advanced timing | 55° BTDC at 5,000 r/min |   |
Advancer type | Throttle position sensor and electrical |   |
Pickup coil resistance/color | 248 - 372 ohms/Gy-B |   |
Transistorized coil ignition unit model (manufacturer) | TNDF69 (DENSO) |   |
Ignition coils |   |   |
Model (manufacturer) | J0313 (DENSO) |   |
Minimum ignition spark gap | 6 mm (0.24 in) |   |
Primary coil resistance | 1.87 - 2.53 ohms |   |
Secondary coil resistance | 12 - 18 k ohms |   |
Spark plug caps |   |   |
Material | Rubber |   |
Resistance | 10 k ohms |   |
Throttle position sensor standard resistance | 4 - 6 k ohms |   |
Charging system |   |   |
System type | AC magneto |   |
Model (manufacturer) | F4T361 (MITSUBISHI) |   |
Normal output | 14 V / 365 W at 5,000 r/min |   |
Stator coil resistance/color | 0.27 - 0.33 ohms at 20°C (68°F)/W-W |   |
Rectifier/regulator |   |   |
Regulator type | Semiconductor short circuit |   |
Model (manufacturer) | SH650C-11 (SHINDENGEN) |   |
No-load regulated voltage | 14.1 - 14.9 V |   |
Rectifier capacity | 18 A |   |
Withstand voltage | 200 V |   |
Battery |   |   |
Battery type | GT14B-4 |   |
Battery voltage/capacity | 12 V / 12 AH |   |
Specific gravity | 1.320 |   |
Headlight type | Halogen bulb |   |
Bulbs (voltage/wattage x quantity) |   |   |
Headlight | 12 V 60 W / 55 W x 2 |   |
Auxiliary light | 12 V 5 W x 2 |   |
Tail/brake light | 12 V 5 W / 21 W x 2 |   |
Front turn signal light | 12 V 8 W / 27 W x 2 |   |
Rear turn signal light | 12 V 27 W x 2 |   |
Meter light | 12 V 2 W x 3 |   |
Indicator light (voltage/wattage x quantity) |   |   |
Neutral indicator light | 14 V 1.4 W x 1 |   |
High beam indicator light | 14 V 1.4 W x 1 |   |
Oil level indicator light | 14 V 1.4 W x 1 |   |
Turn signal indicator light | 14 V 1.4 W x 2 |   |
Fuel indicator light | 12 V 2 W x 1 |   |
Water temperature indicator light | LED |   |
Electric starting system |   |   |
System type | Constant mesh |   |
Starter motor: |   |   |
Model (manufacturer) | SM-13 (MITSUBA) |   |
Power output | 0.8 kW |   |
Brushes: |   |   |
Overall length | 12.5 mm (0.49 in) | 4 mm (0.16 in) |
Spring force | 7.65 - 10.01 N (780 - 1,021 gf, 27.5 - 36.0 oz) |   |
Commutator resistance | 0.025 - 0.035 ohms |   |
Commutator diameter | 28 mm (1.10 in) | 27 mm (1.06 in) |
Mica undercut | 0.7 mm (0.03 in) |   |
Starter relay |   |   |
Model (manufacturer) | MS5F-631 (JIDECO) |   |
Amperage | 180 A |   |
Coil resistance | 4.18 - 4.62 ohms |   |
Starting circuit cutoff relay |   |   |
Model (manufacturer) | G8R-30YM (Omron) |   |
Coil resistance | 180 ohms +/- 10% |   |
Headlight relay |   |   |
Model (manufacturer) | G8H-1C4T-D-ST6-Y48 (Omron) |   |
Coil resistance | 80 ohms +/- 10% |   |
Fuel pump relay |   |   |
Coil resistance | 180 ohms +/- 10% |   |
Horn |   |   |
Horn type | Plain |   |
Model (manufacturer) x quantity | YF-12 (NIKKO) x 1 |   |
Max. amperage | 3 A |   |
Turn signal relay |   |   |
Relay type | Full-transistor |   |
Model (manufacturer) | FE246BH (DENSO) |   |
Self-cancelling device built-in | No |   |
Turn signal blinking frequency | 75 - 95 cycles/min. |   |
Wattage | 27 W x 2 + 3.4 W |   |
Oil level switch |   |   |
Model (manufacturer) | 5LV (DENSO) |   |
Fuel sender |   |   |
Model (manufacturer) | 5LV (NIPPON SEIKI) |   |
Resistance | 4 - 100 ohms at 25°C (77°F) |   |
Sidestand/fuel pump relay |   |   |
Model (manufacturer) | 5EB-20 (OMRON) |   |
Coil resistance | 180 ohms |   |
Fuel pump maximum amperage | 1.2 A |   |
Radiator fan |   |   |
Model (manufacturer) | 4XV (TOYO RADIATOR) |   |
Thermo switch |   |   |
Model (manufacturer) | 5JJ (NIPPON THERMOSTAT) |   |
Fuses (amperage x quantity) |   |   |
Main fuse | 30 A x 1 |   |
Headlight fuse | 20 A x 1 |   |
Signaling system fuse | 20 A x 1 |   |
Ignition fuse | 20 A x 1 |   |
Radiator fan fuse | 10 A x 1 |   |
Turn signal relay fuse | 10 A x 1 |   |
Backup fuse (odometer) | 10 A x 1 |   |
Reserve fuse | 30 A x 1 |   |
  | 20 A x 1 |   |
  | 10 A x 1 |   |
  | Tightening Torque
Item
| Fastener
| Thread Size
| Q'ty
| Nm
| m-Kg
| lb-ft
| | |||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Spark plugs |   | M10 | 4 | 13 | 1.3 | 9.4 | |||||||
Cylinder head | Nut | M10 | 8 | 50 | 5.0 | 36 | |||||||
Cylinder head | Cap nut | M10 | 2 | 50 | 5.0 | 36 | |||||||
Cylinder head | Bolt | M6 | 2 | 12 | 1.2 | 8.7 | |||||||
Camshaft caps | Bolt | M6 | 28 | 10 | 1.0 | 7.2 | |||||||
Cylinder head cover | Bolt | M6 | 6 | 12 | 1.2 | 8.7 | |||||||
Cylinder head (exhaust pipe) | Stud Bolt | M8 | 8 | 15 | 1.5 | 11 | |||||||
Connecting rod caps | Nut | M8 | 8 | 36 | 3.6 | 25 | |||||||
Generator rotor | Bolt | M10 | 1 | 65 + 60° | 6.5 + 60° | 47 + 60° | |||||||
Crankshaft sprocket | Bolt | M10 | 1 | 60 | 6.0 | 43 | |||||||
Cap Bolt (timing chain tensioner) | Bolt | M6 | 1 | 6.4 | 0.64 | 4.6 | |||||||
Camshaft sprocket | Bolt | M7 | 4 | 24 | 2.4 | 17 | |||||||
Water pump inlet pipe | Bolt | M6 | 1 | 10 | 1.0 | 7.2 | |||||||
Water pump outlet pipe | Bolt | M6 | 1 | 10 | 1.0 | 7.2 | |||||||
Oil/water pump assembly driven sprocket | Bolt | M6 | 1 | 15 | 1.5 | 11 | |||||||
Oil pump | Bolt | M6 | 1 | 12 | 1.2 | 8.7 | |||||||
Oil cooler | Bolt | M20 | 1 | 35 | 3.5 | 25 | |||||||
Engine oil drain Bolt | Bolt | M14 | 1 | 43 | 4.3 | 31 | |||||||
Oil strainer housing | Bolt | M6 | 2 | 10 | 1.0 | 7.2 | |||||||
Oil/water pump assembly driven sprocket cover | Bolt | M6 | 1 | 12 | 1.2 | 8.7 | |||||||
Oil delivery pipe | Bolt | M6 | 1 | 10 | 1.0 | 7.2 | |||||||
Oil filter Bolt | Bolt | M20 | 1 | 70 | 7.0 | 51 | |||||||
Oil filter cartridge |   | M20 | 1 | 17 | 1.7 | 12 | |||||||
Oil pipe | Bolt | M6 | 2 | 10 | 1.0 | 7.2 | |||||||
Oil strainer cover | Bolt | M6 | 2 | 10 | 1.0 | 7.2 | |||||||
Air cleaner cap and air cleaner | Screw | M6 | 4 | 6 | 0.6 | 4.3 | |||||||
Frame and air cleaner | Bolt | M6 | 3 | 7 | 0.7 | 5.1 | |||||||
Air cleaner cover and air cleaner | Screw | M6 | 6 | 2 | 0.2 | 1.4 | |||||||
Ring nut and cylinder head | Nut | M8 | 8 | 20 | 2.0 | 14 | |||||||
Exhaust pipe and muffler | Bolt | M8 | 3 | 20 | 2.0 | 14 | |||||||
Emission check Bolt | Bolt | M8 | 4 | 10 | 1.0 | 7.2 | |||||||
EXUP pulley cover | Bolt | M6 | 3 | 10 | 1.0 | 7.2 | |||||||
EXUP cable bracket | Bolt | M6 | 3 | 10 | 1.0 | 7.2 | |||||||
EXUP pulley and shaft arm | Bolt | M5 | 1 | 10 | 1.0 | 7.2 | |||||||
Exhaust joint | Bolt | M4 | 2 | 3 | 0.3 | 2.2 | |||||||
Exhaust pipe assembly | Bolt | M8 | 1 | 20 | 2.0 | 14 | |||||||
Air induction system pipe | Band |   | 4 | 3.5 | 0.35 | 2.5 | |||||||
Crankcase (cylinder head) | Stud Bolt | M10 | 10 | 10 | 1.0 | 7.2 | |||||||
Crankcase | Bolt | M9 | 10 | See Note | See Note | See Note | |||||||
Crankcase | Bolt | M6 | 2 | 14 | 1.4 | 10 | |||||||
Crankcase | Bolt | M6 | 14 | 12 | 1.2 | 8.7 | |||||||
Crankcase | Bolt | M8 | 2 | 24 | 2.4 | 17 | |||||||
AC magneto cover | Bolt | M6 | 9 | 12 | 1.2 | 8.7 | |||||||
Drive sprocker cover | Bolt | M6 | 4 | 10 | 1.0 | 7.2 | |||||||
Plate | Bolt | M6 | 2 | 10 | 1.0 | 7.2 | |||||||
Clutch cover | Bolt | M6 | 8 | 12 | 1.2 | 8.7 | |||||||
Timing chain cap Bolt | Bolt | M6 | 8 | 12 | 1.2 | 8.7 | |||||||
Shift shaft cover | Bolt | M6 | 5 | 12 | 1.2 | 8.7 | |||||||
Breather plate | Bolt | M6 | 5 | 10 | 1.0 | 7.2 | |||||||
Timing mark accessing screw | Bolt | M8 | 1 | 15 | 1.5 | 11 | |||||||
Starter clutch idle gear shaft | Bolt | M6 | 1 | 10 | 1.0 | 7.2 | |||||||
Starter one-way clutch | Bolt | M6 | 3 | 12 | 1.2 | 8.7 | |||||||
Clutch boss (use lock washer) | Nut | M20 | 1 | 90 | 9.0 | 65 | |||||||
Clutch spring | Bolt | M6 | 6 | 8 | 0.8 | 5.8 | |||||||
Drive sprocket (use lock washer) | Nut | M22 | 1 | 85 | 8.5 | 61 | |||||||
Main axle bearing housing | Screw | M6 | 3 | 12 | 1.2 | 8.7 | |||||||
Shift lever stopper | Bolt | M6 | 2 | 10 | 1.0 | 7.2 | |||||||
Stopper screw | Screw | M8 | 1 | 22 | 2.2 | 16 | |||||||
Shift rod (left thread) | Nut | M6 | 1 | 6.5 | 0.65 | 4.7 | |||||||
Shift rod | Nut | M6 | 2 | 6.5 | 0.65 | 4.7 | |||||||
Shift rod joint | Bolt | M6 | 1 | 10 | 1.0 | 7.2 | |||||||
Shift arm | Bolt | M6 | 1 | 10 | 1.0 | 7.2 | |||||||
AC magneto stator coil | Screw | M6 | 3 | 14 | 1.4 | 10 | |||||||
Ignitor unit | Screw | M5 | 2 | 7 | 1.0 | 7.2 | |||||||
Neutral switch |   | M10 | 1 | 20 | 2.0 | 14 | |||||||
Pick up coil | Bolt | M6 | 2 | 10 | 1.0 | 7.2 | |||||||
Thermo unit |   | NPT 1/8" | 1 | 15 | 1.5 | 11 |
Note:
1. First, tighten the bolt to approximately 14.7 Nm (1.5 m-Kg, 11 lb-ft) with a torque wrench
| 2. Tighten another 45 - 50°
| |
  | Tightening Torque
Item
| Thread Size
| Nm
| m-Kg
| lb-ft
| | |||
---|---|---|---|---|---|---|---|---|---|
Upper bracket pinch bolt | M8 | 30 | 3.0 | 22 | |||||
Upper bracket cap nut | M22 | 110 | 11 | 80 | |||||
Upper bracket and handlebar holder | M10 | 32 | 3.2 | 23 | |||||
Handlebar holder | M8 | 23 | 2.3 | 17 | |||||
Lower bracket pinch bolt |   | 23 | 2.3 | 17 | |||||
Lower bracket ring nut (See Note) | M25 | 18 | 1.8 | 13 | |||||
Front brake master cylinder | M6 | 10 | 1.0 | 7.2 | |||||
Front brake hose union bolt | M10 | 30 | 3.0 | 22 | |||||
Engine Mounting: |   |   |   |   | |||||
Engine mounting bolt/nut | M10 | 55 | 5.5 | 40 | |||||
Engine mounting bolt/nut | M8 | 33 | 3.3 | 24 | |||||
Frame and down tube | M10 | 89 | 8.9 | 64 | |||||
Clutch cable lock nut | M8 | 7 | 0.7 | 5.1 | |||||
Ignition coil and stay | M6 | 7 | 0.7 | 5.1 | |||||
Pivot shaft | M18 | 125 | 12.5 | 90 | |||||
Rear shock absorber (upper) | M10 | 40 | 4.0 | 29 | |||||
Rear shock absorber and relay arm | M10 | 40 | 4.0 | 29 | |||||
Relay arm and frame | M10 | 40 | 4.0 | 29 | |||||
Relay arm and connecting arm | M12 | 48 | 4.8 | 35 | |||||
Connecting arm and swing arm | M12 | 48 | 4.8 | 35 | |||||
Drive chain guard | M6 | 7 | 0.7 | 5.1 | |||||
Drive chain case | M6 | 7 | 0.7 | 5.1 | |||||
Fuel cock | M6 | 7 | 0.7 | 5.1 | |||||
Fuel sender | M5 | 4 | 0.4 | 2.9 | |||||
Side cover | M6 | 4 | 0.4 | 2.9 | |||||
Coolant reservoir tank | M6 | 4 | 0.4 | 2.9 | |||||
Front wheel axle | M16 | 72 | 7.2 | 52 | |||||
Front wheel axle pinch bolt | M8 | 23 | 2.3 | 17 | |||||
Front brake caliper | M10 | 40 | 4.0 | 29 | |||||
Front brake disk | M6 | 18 | 1.8 | 13 | |||||
Front brake bleed screw | M8 | 6 | 0.6 | 4.3 | |||||
Rear brake torque rod | M8 | 23 | 2.3 | 17 | |||||
Rear wheel sprocket | M10 | 69 | 6.9 | 50 | |||||
Drive chain adjusting nut | M8 | 16 | 1.6 | 12 | |||||
Rear brake caliper | M10 | 40 | 4.0 | 29 | |||||
Rear wheel axle | M24 | 150 | 15 | 108 | |||||
Rear brake hose union bolt | M10 | 30 | 3.0 | 22 | |||||
Rear brake bleed screw | M8 | 6 | 0.6 | 4.3 | |||||
Rear brake disk | M8 | 23 | 2.3 | 17 | |||||
Rider footrest bracket and frame | M8 | 30 | 3.0 | 22 | |||||
Rear brake reservoir tank | M6 | 4 | 0.4 | 2.9 | |||||
Rear brake master cylinder | M8 | 23 | 2.3 | 17 | |||||
Rider footrest and bracket | M10 | 55 | 5.5 | 40 | |||||
Passenger footrest bracket and frame | M8 | 28 | 2.8 | 20 | |||||
Passenger footrest bracket and muffler | M10 | 48 | 4.8 | 35 |
Note:
1. First, tighten the ring nut to approximately 52 Nm (5.2 m-Kg, 38 lb-ft) with a torque wrench
| 2. Loosen the ring nut completely
| 3. Retighten the ring nut to specification
| |
Last Updated: 05-30-2002
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