Maintenance Specifications -- Chassis

1.
a.
b.

c.

Steering System
Steering Bearing Type 
No./Size of Steel Balls
    Upper
    Lower 
Lock-to-lock Angle

Ball Bearing

19 pcs/ 1/4 in 
19pcs/ 1/4 in 
38.5"

2. 
a. 
b. 
c.

d. 
e.

f. 
g.

Front Suspension
Front Fork Travel
Fork Spring Free Length
Spring Rate/Stroke 
    K1
    K2
Optional Spring
Oil Capacity
or
Oil Level

Oil Grade
Enclosed Air Pressure

140 mm (5.51 in)
449 mm (17.7 in)

4.13 N/mm (0.421 kg/mm. 23.6 lb/in) / 0~100 mm (0-3.94 in)
7.36 N/mm (0.75 kg/mm, 42.0 lb/in) / 100~140 mm (3.94- 5-51 in)
No.
2381 4 cc (8.04 t 0.14 US oz)

180 mm (7.09 in)
(From top of inner tube fully compressed without spring.)
Yamaha fork oil (10) wt or equivalent SAE 10W30 motor oil
39 kPa (0.4 kg/cm³. 5.7 psi)

3. 
a. 
b. 
c.

d.

Rear Suspension 
Shock Absorber Travel 
Spring Free Length 
Spring Rate/
Stroke
Optional Spring

80 mm (3.15 in)
251.6 mm (9.90 in)
13.7 N/mm (1.4 kg/mm, 78.4 lb/in)/
0-80 mm (0- 3.15 in)
No.

4. 
a.
 

Rear Arm
Swing Arm Free Play Limit 
    -End 
    -Side

0 mm (0 in) 
0 mm (0 in)

5.
a.
b. 
c.

Wheel
Front Wheel Type 
Rear Wheel Type 
Front Rim Size/Material 
Rear Rim Size/Material 
Rim Runout Limit 
    - Vertical 
    - Lateral

Cast Wheel
Cast Wheel
MT1.85x 19/Steel. Aluminum
MT2.15 x 18/Steel. Aluminum

<0.5mm (0.02 in)>
< 1.0 mm (0.04 in)>

c.

6.8 mm {0.27 in)
<0.8mm (0.032 in) >

d.
f.

Master Cylinder Inside Dia.
Front Caliper Cylinder inside Dia.
Front Brake Fluid Type

15.87 mm (0.62 in)
38.18 mm (1.50 in) 
DOT# 3

6.2. 
a. 
b.
c.
d.

Drum Brake
Type 
    Rear
Drum Inside Dia.
    Rear 
Lining Thickness 
    < Limit > 
Shoe Spring Free Length 
    Rear

Leading trailing

200 mm (7.87 in) 
4 mm (0.16 in) 
<2mm (0.08 in) > 

68 mm (2.68 in)

7.
a. 
b. 
c.

Brake Lever & Brake Pedal 
Brake Lever Free Play 
Brake Pedal Free Play
 Brake Pedal Position

5.0-8.0 mm (0.2-0.3 in)
20- 30 mm (0.8-1.2 in)
40 mm (1.6 in)
(Vertical height below footrest top.)

8.

Clutch Lever Free Play

2- 3 mm (0.08-0.12 in)

Part to be tightened

Part name

Thread size

Q'ty

Tightening 
torque

Remarks

Engine mounting bolt:

Front, upper

Nut

M10 P1.25

1

4.2

30.4

Front, under

Nut

M10 P1.25

2

4.2

30.4

Rear

Nut

M10 P1.25

2

7.0

50.6

Engine mounting stay:

Front

Nut

M8 P1.25

4

2.0

14.5

Handle crown & Steering shaft

Bolt 
Nut

M14 P1.25 
M8 P1.25

1 
1

5.4 
2.0

39.1 
14.5

Handle crown & Inner tube

Nut

M8 P1.25

1

2.0

14.5

Handle crown & Handle holder

Bolt

M8 P1.25

2

2.0

14.5

Front fork:

Under bracket & Inner tube

Bolt

M8 P1.25

4

2.0

14.5

Front wheel shaft

Nut castle

M14 P1.5

1

10.7

77.4

Front wheel axle pinch bolt

Nut salf locking

M8 P1.25

2

2.0

14.5

Pivot shaft

Bolt

M22 P1.5

1

0.55

4.0

Taper roller 
bearing

Rear wheel shaft

Nut castle

M14 P1.5

1

10.7

77.4

Rear shock absorber (Upper)

Nut cap

M10 P1.25

2

3.0

21.7

Rear shock absorber (Lower)

L Nut cap R Bolt

M10 P1.25

2

3.0

21.7

Footrest

Bolt

M10 P1.25

2

4.2

30.4

Tension bar & Brake plate

Bolt

M8 P1.25

1

2.0

14.5

Tension bar & Rear arm

Bolt

M8 P1.25

1

2.0

14.5

Camshaft lever & Camshaft

Bolt

M6 P1.0

1

0.9

6.5

Disc brake section:

Brake disc & Hub (Front)

Bolt

M8 P1.25

12

2.0

14.5

Lock washer

Master cylinder & 
Brake hose (Front)

Bolt union

M10 P1.25

1

2.0

14.5

Brake hose & Joint

Bolt union

M10 P1.25

1

2.6

18.8

Caliper & Brake hose

Bolt union

M10 P1.25

1

2.6

18.8

Caliper & Front fork (Front)

M8 P1.25

1

2.6

19

Caliper bleed screw (Front)

M8 PI.25

1

0.6

4.3

DEFINITION OF TERMS:

m-kg

= Meter-kilogram(s) (usually torque)

9

= Gram(s)

kg

= Kilogram(s) (1,000 grams)

lit

= Liter(s)

km/lit

= Kilometer(s) per liter (fuel consumption)

cc

= Cubic centimeter(s) (cm³) (volume or capacity)

kg/mm

= Kilogram(s) per milimeter (usually spring compression rate)

kg/cm²

= Kilogram(s) per square centimeter (pressure)

Part to be tightened

Part name

Thread size

Q'ty

Tightening torque

Remarks

Nm

m-kg

ft-lb

Valve seat & Crankcase 
Relief valve & Valve seat 
Union bolt & Turbocharger 
Oil pipe & Turbocharger 
Oil pipe & Crankcase 
Oil pipe clamp crankcase 
Regulator stay 1 & Frame 
Regulator & Regulator stay 
Check valve & Regulator stay 
Carburetor & Regulator stay

---
Union bolt 
Union bolt 
Bolt 
Bolt 
Screw 
Hex. bolt 
Hex. nut 
Screw 
Screw

PT1/8
M16 P1.5 
M10 P1.25 
M6 P1.0 
M6 P1.0
M6 P1.0 
M6 P1.0
M12 P1.25 
M5 P0.8 
M6 P1.0

1
1 
1 
2 
2 
1 
2 
1 
1 
2

26 20
21
12
12
7
12
18
4
7

2.6 
2.0 
2.1 
1.2 
1.2 
0.7 
1.2 
1.8 
0.4 
0.7

19
14
15
8.7
8.7
5.1
8.7
13
2.9
5.1

Apply Loctite

Clamp:

Air filter case & Surge tank 
Turbo duct 2 & Surge tank 
Carburetor & Surge tank 
Drain valve & Surge tank 
Reed valve cover & Surge tank 
Air filter stay & Frame 
Air filter case & Stay 
Air filter case& Stay 
Air cleaner stay & Frame

Screw 
Screw
Screw 
Screw
Bolt 
Bolt
Screw
Screw
Bolt

M4 P0.7 
M4 P0.7 
M4 P0.7 
M5 P0.8 
M6 P1.0 
M6 P1.0 
M6 P1.0 
Tapping
M6 P1.0

2 
2
8 
2 
5 
1 
1 
2 
2

2 
2 
2 
4
12
7 
5 
4
12

0.2 
0.2 
0.2 
0.4 
1.2 
0.7 
0.5 
0.4 
1.2

1.4 
1.4 
1.4 
2.9 
8.7 
5.1
3.6
2.9
8.7

Clamp:

Turbo duct 1 & Turbocharger 
Turbo duct 1 & Air cleaner 
Turbo duct 2 & Turbocharger 
Carb. joint & Carburetor 
Fuel pump & Stay 
Muffler & Foot rest bracket 
Frame & Foot rest bracket 
Frame & Exhaust chamber 
Turbocharger & Exhaust chamber 
Turbocharger & Muffler 
Turbocharger & Muffler 
Sub-muffler & Protecter 
Silencer cap & Muffler

Screw
Screw
Screw
Screw
Screw
Flange bolt
Bolt
Flange bolt
Nut
Bolt
Nut
Bolt
Bolt

M4 Po.7 
M4 P0.7 
M4 P0.7 
M4 P0.7 
M5 P0.8 
M10 PI.25
 M8 Pi.25 
M10 Pi .25 
M8 Pi.25 
M8 Pi.25 
M8 Pi .25 
M6 Pl.O 
M6 Pl.O

1 
1 
2
4
1
3
1
1
2
1
2
3
4

2
2
2
2
4
25
20
25
20
20
20
12
12

0.2 
0.2 
0.2 
0.2 
0.4 
2.5 
2.0 
2.5 
2.0 
2.0 
2.0 
1.2 
1.2

1.4
1.4
1.4
1.4
2.9
18
14
18
14
14
14
8.7
8.7