Item | Standard | Limit |
Cylinder head: | ||
Warp limit* | ••• | 0.03 mm |
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Cylinder: | ||
Bore size | 95.00-95.01 mm | 95.1 mm |
Measuring point* | 40 mm | ••• |
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Camshaft: | ||
Drive method | Chain drive (left & right) | ••• |
Cam cap inside diameter | 25.000-25.021 mm | ••• |
Camshaft outside diameter | 24.96-24.98 mm | ••• |
Shaft-to-cap clearance | 0.020-0.061 mm | ••• |
Cam dimensions | ||
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Intake | ||
"A" | 39.112-39.212 mm | 39.012 mm |
"B" | #1: 32.093-32.193 mm | #1: 31.993 mm |
#2: 32.127-32.227 mm | #2: 32.027 mm | |
"C" | 7.162 mm | 7.012 mm |
Exhaust | ||
"A" | 39.145-39.245 mm | 39.045 mm |
"B" | 32.200-32.300 mm | 32.100 mm |
"C" | 7.195 mm | 7.045 mm |
Camshaft runout limit | ••• | 0.03 mm |
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Timing chain: | ||
Timing chain type/No. of links | SILENT CHAIN/98L | ••• |
Timing chain adjustment method | Automatic | ••• |
Rocker arm/rocker arm shaft: | ||
Bearing inside diameter | 14.000 mm-14.018 mm | 14.036 mm |
Shaft outside diameter | 13.985 mm-13.991 mm | 13.95 mm |
Arm-to-shaft clearance | 0.009 mm-0.033 mm | 0.086 mm |
Valve, valve seat, valve guide: | ||
Valve clearance (cold) | ||
IN | 0.07-0.12 mm | ••• |
EX | 0.12-0.17 mm | ••• |
Valve dimensions: | ||
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"A" head diameter | ||
IN | 47.0~47.2 mm | ••• |
EX | 39.0~39.2 mm | ••• |
"B" face width | ||
IN | 2.1 mm | ••• |
EX | 2.1 mm | ••• |
"C" seat width | ||
IN | 1.2~1.4 mm | 1.8 mm |
EX | 1.2~1.4 mm | 1.8 mm |
"D" margin thickness | ||
IN | 1.1~1.5 mm | 0.8 mm |
EX | 1.1~1.5 mm | 0.8 mm |
Stem outside diameter | ||
IN | 7.975~7.990 mm | ••• |
EX | 7.960~7.975 mm | ••• |
Guide inside diameter | ||
IN | 8.000~8.012 mm | ••• |
EX | 8.000~8.012 mm | ••• |
Stem-to-guide clearance | ||
IN | 0.010~0.037 mm | 0.08 mm |
EX | 0.025~0.052 mm | 0.10 mm |
Stem runout limit | ••• | 0.03 mm |
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Valve seat width | ||
IN | 1.2-1.4 mm | 2.0 mm |
EX | 1.2-1.4 mm | 2.0 mm |
Valve spring: | ||
Free length | ||
IN | 44.6 mm | 43.5 mm |
EX | 44.6 mm | 43.5 mm |
Set length (valve closed) | ||
IN | 40 mm | ••• |
EX | 40 mm | ••• |
Compressed pressure | ||
IN | 160.7 N (16.4 kg) | ••• |
(installed) EX | 160.7 N (16.4 kg) | ••• |
Tilt limit* | ||
IN | ••• | 2.5°/1.9mm |
EX | ••• | 2.5°/1.9mm |
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Direction of winding (top view) | ||
IN | Clockwise | ••• |
EX | Clockwise | ••• |
Piston: | ||
Piston to cylinder clearance | 0.025-0.050 mm | 0.15 mm |
Piston size "D" | 94.960-94.975 mm | ••• |
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Measuring point "H" | 5 mm | ••• |
Piston off-set | 0 mm | ••• |
Piston pin bore inside diameter | 22.004-22.015 mm | ••• |
Piston pin outside diameter | 21.991-22.000 mm | ••• |
Piston rings: | ||
Top ring:![]() | ||
Type | Plain | ••• |
Dimensions (B x T) | 1.5 x 3.8 mm | ••• |
End gap (installed) | 0.3-0.5 mm | 0.8 mm |
Side clearance (installed) | 0.04-0.08 mm | 0.1 mm |
2nd ring:![]() | ||
Type | Taper | ••• |
Dimensions (B x T) | 1.2 x 3.8 mm | ••• |
End gap (installed) | 0.30-0.45 mm | 0.8 mm |
Side clearance | 0.03-0.07 mm | 0.1 mm |
Oil ring:![]() | ||
Dimensions (B x T) | 2.5 x 3.4 mm | ••• |
End gap (installed) | 0.2-0.7 mm | ••• |
Connecting rod: | ||
Oil clearance | 0.044-0.073 mm | ••• |
Color code (corresponding size) | (1) Blue (2) Black (3) Brown (4) Green (5) Yellow | ••• |
Crankshaft:![]() | ||
Crank width "A" | 101.95-102.00 mm | ••• |
Runout limit "C" | ••• | 0.02 mm |
Big end side clearance "D" | 0.320-0.474 mm | ••• |
Clutch: | ||
Friction plate thickness | 2.9-3.1 mm | 2.8 mm |
Quantity | 8 | ••• |
Clutch plate thickness | 2.5-2.7 mm | 0.1 mm |
Quantity | 1 | ••• |
Clutch plate thickness | 1.9-2.1 mm | 0.1 mm |
Quantity | 7 | |
Clutch spring free length | 7.2 mm | 6.5 mm |
Quantity | 1 | ••• |
Clutch housing thrust clearance | 0.05-0.40 mm | ••• |
Clutch housing radial clearance | 0.010-0.044 mm | ••• |
Clutch release method | Inner push, screw push | ••• |
Push rod bending limit | ••• | 0.5 mm |
Transmission: | ||
Main axle deflection limit | ••• | 0.08 mm |
Drive axle deflection limit | ••• | 0.08 mm |
Shifter: | ||
Shifter type | Guide bar | ••• |
Carburetor: | ||
I. D. mark | 5EL1 00 | ••• |
Main jet (M.J) | #1: #110, #2: #112.5 | ••• |
Main air jet (M.A.J) | #55 | ••• |
Jet needle (J.N) | #1: 5DL39-53-3/5, #2: 5DL40-53-3/5 | ••• |
Needle jet (N.J) | P-0M | ••• |
Pilot air jet | ||
(P.A.J.1) | #63.8 | •••• |
(P.A.J.2) | #145 | •••• |
Pilot outlet (P.O) | 1.0 | ••• |
Pilot jet (P.J) | #17.5 | ••• |
Bypass 1 (B.P.1) | 0.8 | ••• |
Bypass 2 (B.P.2) | 0.8 | ••• |
Bypass 3 (B.P.3) | 0.8 | ••• |
Pilot screw (P.S) | 3 | ••• |
Valve seat size (V.S) | 1.2 | ••• |
Starter jet (G.S.1) | #42.5 | ••• |
Starter jet (G.S.2) | 0.8 | ••• |
Throttle valve size (Th.V) | #125 | ••• |
Fuel level (F.L) | 4~5 mm | ••• |
Engine idle speed | 950-1,050 r/min | ••• |
Intake vacuum | 34.7-37.3 kPa (260-280 mmHg) | ••• |
Engine oil temperature | 75-85°C | ••• |
Fuel pump: | ||
Type | Electrical type | ••• |
Model/manufacturer | UC-Z6M/MITSUBISHI | ••• |
Consumption amperage (max) | 0.8 A | ••• |
Output pressure | 12 kPa (0.12 kg/cm²) | ••• |
Lubrication system: | ||
Oil filter type | Paper type | ••• |
Oil pump type | Trochoid type | ••• |
Tip clearance "A" or "B" | 0.03-0.09 mm | 0.15 mm |
Side clearance | 0.03-0.08 mm | 0.15 mm |
Relief valve operating pressure | 450-550 kPa (4.5-5.5 kg/cm²) | ••• |
Shaft drive: | ||
Middle gear backlash | 0.1-0.2 mm | ••• |
Final gear backlash | 0.1-0.2 mm | ••• |
Lubrication chart
![](https://motoinstruction.ru/img/yamaha/16/122140.jpg)
Cylinder head tightening sequence
![](https://motoinstruction.ru/img/yamaha/16/122141.jpg)
Crankcase tightening sequence
![]() Left crankcase | ![]() Right crankcase |
Tightening torques
Part to be tightened | Part name | Thread size | Quantity | Tightening torque | Remarks | |
N·m | m·kg | |||||
Cylinder head | Nut | M12 | 8 | 50 | 5.0 | |
Cylinder head | Nut | M10 | 2 | 35 | 3.5 | |
Plate | Bolt | M8 | 2 | 20 | 2.0 | |
Cylinder head cover | Screw | M6 | 4 | 4 | 0.4 | |
Cylinder head (exhaust pipe) | Stud bolt | M8 | 4 | 12.5 | 1.25 | |
Rocker arm shaft | Union bolt | M16 | 2 | 37.5 | 3.75 | |
Camshaft sprocket cover | Bolt | M6 | 4 | 10 | 1.0 | |
Tappet cover | Bolt | M6 | 8 | 10 | 1.0 | |
Rocker arm shaft (oil passage) | Bolt | M16 | 4 | 38 | 3.8 | |
Stopper plate (camshaft) | Bolt | M8 | 4 | 20 | 2.0 | Use lock washer |
Spark plug | — | M14 | 2 | 20 | 2.0 | |
Cylinder | Bolt | M6 | 2 | 10 | 1.0 | |
Lower cylinder head cover | Bolt | M6 | 6 | 10 | 1.0 | |
Upper cylinder head cover | Screw | M6 | 8 | 5 | 0.5 | |
Connecting rod | Nut | M9 | 4 | 48 | 4.8 | |
Rotor | Nut | M16 | 1 | 175 | 17.5 | |
Valve adjusting locknut | Nut | M8 | 4 | 27 | 2.7 | |
Camshaft sprocket | Bolt | M10 | 2 | 55 | 5.5 | |
Timing chain tensioner | Bolt | M6 | 4 | 10 | 1.0 | |
Timing chain tentioner cap | Bolt | M6 | 2 | 8 | 0.8 | |
Timing chain guide | Bolt | M6 | 4 | 10 | 1.0 | |
Oil pump | Bolt | M6 | 3 | 10 | 1.0 | |
Oil strainer cover | Bolt | M6 | 3 | 10 | 1.0 | |
Oil filter cover | Bolt | M6 | 5 | 10 | 1.0 | |
Oil pump gear | Bolt | M6 | 1 | 12 | 1.2 | |
Oil pump cap | Bolt | M6 | 1 | 10 | 1.0 | |
Oil deliuery pipe (cylinder head) | Union bolt | M16 | 2 | 20 | 2.0 | |
Oil deliuery pipe (crankcase) | Union bolt | M10 | 1 | 20 | 2.0 | |
Drain bolt | — | M14 | 1 | 43 | 4.3 | |
Carburetor cover | Bolt | M5 | 2 | 7 | 0.7 | |
Air filter case stay | Bolt | M6 | 2 | 10 | 1.0 | |
Air filter case assembly | Bolt | M5 | 3 | 2 | 0.2 | |
Exhaust pipe joint and cylinder head | Nut | M8 | 4 | 20 | 2.0 | |
Exhaust pipe joint and muffler assembly | Bolt | M8 | 2 | 20 | 2.0 | |
Muffler | Bolt | M10 | 2 | 25 | 2.5 | |
Crankcase (cylinder) | Stud bolt | M12 | 8 | 24 | 2.4 | |
Crankcase (cylinder) | Stud bolt | M10 | 2 | 20 | 2.0 | |
Crankcase | Bolt | M10 | 3 | 38.5 | 3.85 | |
Crankcase | Bolt | M6 | 10 | 10 | 1.0 | |
Bearing retainer (middle drive pinion gear) | Bolt | M8 | 3 | 25 | 2.5 | |
Crankcase cover (left) | Bolt | M6 | 13 | 10 | 1.0 | |
Crankcase cover (right) | Bolt | M6 | 11 | 10 | 1.0 | |
Clamp | Bolt | M6 | 1 | 10 | 1.0 | |
One-way clutch | Bolt | M6 | 8 | 12 | 1.2 | |
Primary drive gear | Nut | M20 | 1 | 110 | 11.0 | Use lock washer |
Clutch spring | Bolt | M6 | 6 | 8 | 0.8 | |
Clutch adjuster | Nut | M8 | 1 | 12 | 1.2 | |
Clutch boss | Nut | M20 | 1 | 70 | 7.0 | Use lock washer |
Push lever axle | Screw | M8 | 1 | 12 | 1.2 | |
Middle drive pinion gear | Nut | M44 | 1 | 110 | 11.0 | Stake |
Bearing retainer (middle driven shaft) | Nut | M88 | 1 | 110 | 11.0 | Stake |
Yoke (middle driven shaft) | Nut | M14 | 1 | — | — | Stake |
Bearing housing (middle drive shaft) | Bolt | M8 | 4 | 25 | 2.5 | |
Shift lever stopper | Bolt | M8 | 1 | 22 | 2.2 | Use lock washer |
Guide bar stopper | Screw | M6 | 2 | 7 | 0.7 | |
Shift dram segment | Screw | M5 | 1 | 4 | 0.4 | |
Shift arm | Bolt | M6 | 1 | 10 | 1.0 | |
Shift pedal adjuster | Nut | M6 | 2 | 10 | 1.0 | 1 of 2 has LH thread |
Stator coil | Screw | M6 | 3 | 10 | 1.0 | |
Pickup coil | Screw | M5 | 2 | 7 | 0.7 | |
Starter motor | Bolt | M6 | 2 | 10 | 1.0 | |
Neutral switch | — | M10 | 1 | 20 | 2.0 | |
Ignition coil | Screw | M5 | 4 | 2.5 | 0.25 | |
Speed sensor | Bolt | M6 | 1 | 7 | 0.7 |