Chapter 7, APPENDICES
Chapter 7, APPENDICESMaintenance Specifications -- Chassis
Maintenance Specifications -- ChassisChassis
Steering System: Steering Bearing Type |
Taper Roller Bearing |
|
Front Suspension: (Each) Front Fork Travel Fork Spring Free Length 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) 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) |
|
Rear Arm: Swingarm Free Play Limit: |
1.0 mm (0.04 in) |
|
Wheel: Front Wheel Type Rear Wheel Type Front Rim Size/Material Rear Rim Size/Material Rim Runout Limit: |
Cast Wheel Cast Wheel MT2.15x 19/Aluminum MT3.00x 16/Aluminum
2.0 mm (0.08 in) |
|
Disc Brake: Outside Dia. x Thickness |
Dual disc 267 x 5 mm (10.5 x 0.2 in) |
|
Pad Thickness:
|
Inner Outer |
5.5 mm (0.22 in) 5.5 mm (0.22 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: |
Nut |
M10 P1.25 M10P1.25 |
1 |
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) |
I |
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 SpecificationsGENERAL 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 |
Newton meter |
N x m |
Torque |
Pa N/mm |
Pascal Newton per millimeter |
N/m2 N/mm |
Pressure Spring rate |
L cm3 |
Liter Cubic centimeter |
|
Volume or Capacity |
r/min |
Rotation per minute |
|
Engine Speed |