Yamaha YZF-R1 2004 Operating and installation instructions

Yamaha Motor Co., Ltd.
2004
YZF-R1(S)
5VY1-SE1
SERVICE
INFORMATION

Yamaha Motor Co., Ltd.
FOREWORD
This service information has been prepared to introduce new service and data for the
YZF-R1(S) 2004. For complete service information procedures, it is necessary to use
this Service Information together with the following manual.
YZF-R1(S) 2004 SERVICE MANUAL: 5VY1-ME1

NOTE:
WARNING
CAUTION:
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
16 1715
1413
11 12
10
GEN
INFO SPEC
ENG
FI ELEC
COOL
CHK
ADJ
TRBL
SHTG
CHAS
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Fuel injection system
8Electrical system
9Troubleshooting
Symbols 10 to 17 indicate the following.
10 Serviceable with engine mounted
11 Filling fluid
12 Lubricant
13 Special tool
14 Tightening torque
15 Wear limit, clearance
16 Engine speed
17 Electrical data
Symbols 18 to 23 in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
18 Engine oil
19 Gear oil
20 Molybdenum-disulfide oil
21 Wheel-bearing grease
22 Lithium-soap-based grease
23 Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indi-
cate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part

CONTENTS
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 19
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . . 26
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . . . 42
YZF-R1(S) 2004 WIRING DIAGRAM

1-1
MOTORCYCLE IDENTIFICATION GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is stamped
into the right side of the steering head pipe.
EAS00018
MODEL LABEL
The model label 1is affixed to the frame. This
information will be needed to order spare parts.
1

2-1
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5VY1 (EUR), 5VY2 (FRA), 5VY3 (AUS) SSS
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,065 mm (8.13 in)
720 mm (28.3 in)
1,105 mm (43.5 in)
835 mm (32.9 in)
1,395 mm (54.9 in)
135 mm (5.31 in)
3,400 mm (133.9 in)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Weight
Wet (with oil and a full fuel tank)
Maximum load (except motorcycle)
193 kg (425 lb)
202 kg (445 lb)
SSS
SSS
2

2-2
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type
Displacement
Cylinder arrangement
Bore stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Liquid-cooled, 4-stroke, DOHC
998 cm3(60.90 cu.in)
Forward-inclined parallel 4-cylinder
77.0 53.6 mm (3.03 2.11 in)
12.4 : 1
1,150 X1,250 r/min
22 kPa (165 mmHg, 6.5 inHg)
1,480 kPa (14.80 kg/cm2,14.80 bar,
210.5 psi) at 350 r/min
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Premium unleaded gasoline only
18 L (3.96 Imp gal, 4.76 US gal)
3.4 L (0.75 Imp gal, 0.90 US gal)
SSS
SSS
SSS
Engine oil
Lubrication system
Recommended oil
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure
Engine oil temperature
Relief valve opening pressure
Wet sump
SAE 20W40 SE or SAE10W30SE
API service SE, SF, SG type or higher
3.8 L (3.35 Imp qt, 4.02 US qt)
2.9 L (2.55 Imp qt, 3.07 US qt)
3.1 L (2.73 Imp qt, 3.28 US qt)
230 kPa at 5,000 r/min
(2.3 kg/cm2at 5,000 r/min)
(2.3 bar at 5,000 r/min)
(32.7 psi at 5,000 r/min)
100_C (212_F)
600 X680 kPa (6.0 X6.8 kg/cm2,
6.0 X6.8 bar, 87.0 X98.6 psi)
SSS
SSS
SSS
SSS
SSS
3

2-3
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Oil filter
Oil filter type
Bypass valve opening pressure
Paper
80 X120 kPa (0.8 X1.2 kg/cm2,
0.8 X1.2 bar, 11.6 X17.4 psi)
SSS
SSS
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance
Trochoid
0.01 X0.10 mm
(0.0004 X0.0039 in)
0.09 X0.15 mm
(0.00035 X0.0059 in)
SSS
0.18 mm
(0.0071 in)
0.22 mm
(0.0087 in)
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
Water pump
Water pump type
Reduction ratio
Max. impeller shaft tilt
2.51 L (2.21 Imp qt, 2.65 US qt)
108 X137 kPa (1.08 X1.37 kg/cm2,
1.0 X1.3 bar, 15.6 X19.9 psi)
380 mm (14.96 in)
258 mm (10.2 in)
24 mm (0.94 in)
0.25 L (0.22 Imp qt, 0.26 US qt)
Single suction centrifugal pump
65/43 25/32 (1.181)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
0.15 mm
(0.006 in)
Starting system type Electric starter
Spark plugs
Model (manufacturer) quantity
Spark plug gap
CR9EK (NGK) 4
0.6 X0.7 mm (0.0236 X0.0276 in)
SSS
SSS
Cylinder head
Volume
Max. warpage
12.5 X13.1 cm3(0.76 X0.80 cu.in)
SSS
SSS
0.10 mm
(0.0039 in)
4

2-4
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-
cap clearance
Intake camshaft lobe dimensions
Measurement A
Measurement B
Exhaust camshaft lobe dimensions
Measurement A
Measurement B
Max. camshaft runout
Chain drive (right)
22.500 X22.521 mm (0.8858 X0.8867 in)
22.459 X22.472 mm (0.8842 X0.8847 in)
0.028 X0.062 mm (0.0011 X0.0024 in)
32.85 X32.95 mm (1.293 X1.297 in)
25.14 X25.24 mm (0.990 X0.994 in)
30.75 X30.85 mm (1.211 X1.215 in)
23.09 X23.19 mm (0.909 X0.913 in)
SSS
SSS
SSS
SSS
32.75 mm
(1.289 in)
25.04 mm
(0.986 in)
30.65 mm
(1.207 in)
22.99 mm
(0.905 in)
0.03 mm
(0.0012 in)
5

2-5
ENGINE SPECIFICATIONS SPEC
Head Diameter Face Width Seat Width Margin Thickness
Item Standard Limit
Timing chain
Model/number of links
Tensioning system
RH2020/122
Automatic
SSS
SSS
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
0.11 X0.20 mm (0.0043 X0.0079 in)
0.21 X0.25 mm (0.0083 X0.0098 in)
SSS
SSS
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
23.4 X23.6 mm (0.9213 X0.9291 in)
24.9 X25.1 mm (0.9803 X0.9882 in)
1.76 X2.90 mm (0.0693 X0.1142 in)
1.76 X2.90 mm (0.0693 X0.1142 in)
0.9 X1.1 mm (0.0354 X0.0433 in)
0.9 X1.1 mm (0.0354 X0.0433 in)
0.5 X0.9 mm (0.0197 X0.0354 in)
0.5 X0.9 mm (0.0197 X0.0354 in)
3.975 X3.990 mm (0.1565 X0.1571 in)
4.460 X4.475 mm (0.1756 X0.1762 in)
4.000 X4.012 mm (0.1575 X0.1580 in)
4.500 X4.512 mm (0.1772 X0.1776 in)
0.010 X0.037 mm (0.0004 X0.0015 in)
0.025 X0.052 mm (0.0010 X0.0020 in)
SSS
0.9 X1.1 mm (0.0354 X0.0433 in)
0.9 X1.1 mm (0.0354 X0.0433 in)
SSS
SSS
SSS
SSS
1.6 mm (0.06 in)
1.6 mm (0.06 in)
0.5 mm (0.02 in)
0.5 mm (0.02 in)
3.945 mm
(0.1553 in)
4.425 mm
(0.1742 in)
4.050 mm
(0.1594 in)
4.550 mm
(0.1791 in)
0.08 mm
(0.0032 in)
0.10 mm
(0.0039 in)
0.01 mm
(0.0004 in)
1.6 mm (0.06 in)
1.6 mm (0.06 in)
6

2-6
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Valve springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force
(installed)
Intake
Exhaust
Spring tilt
Intake
Exhaust
Winding direction (top view)
Intake
Exhaust
39.3 mm (1.55 in)
39.3 mm (1.55 in)
32.7 mm (1.29 in)
32.8 mm (1.29 in)
145.9 X167.9 N (14.88 X17.12 kg,
32.80 X37.74 lb)
164.1 X188.9 N (16.73 X19.26 kg,
36.89 X42.46 lb)
SSS
SSS
Clockwise
Clockwise
37.3 mm (1.47 in)
37.3 mm (1.47 in)
SSS
SSS
SSS
SSS
2.5_/1.7 mm
(0.07 in)
2.5_/1.7 mm
(0.07 in)
SSS
SSS
Cylinders
Cylinder arrangement
Bore stroke
Compression ratio
Bore
Max. out-of-round
Forward-inclined, parallel 4-cylinder
77.0 mm 53.6 mm (3.03 2.11 in)
12.4 : 1
77.00 X77.01 mm (3.0315 X3.0319 in)
SSS
SSS
SSS
SSS
SSS
0.005 mm
(0.0002 in)
7

2-7
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Piston
Piston-to-cylinder clearance
Diameter D
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore
clearance
Piston rings
Top ring
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
2nd ring
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
Oil ring
Dimensions (B T)
End gap (installed)
0.010 X0.035 mm (0.0004 X0.0014 in)
76.975 X76.990 mm (3.0305 X3.0311 in)
5 mm (0.20 in)
17.002 X17.013 mm
(0.6694 X0.6698 in)
0.5 mm (0.0197 in)
Intake side
16.991 X17.000 mm
(0.6689 X0.6693 in)
0.002 X0.022 mm (0.0001 X0.0009 in)
Barrel
0.90 2.75 mm (0.04 0.11 in)
0.15 X0.25 mm (0.0059 X0.0098 in)
0.030 X0.065 mm (0.0012 X0.0026 in)
Taper
0.80 2.75 mm (0.03 0.11 in)
0.30 X0.45 mm (0.0118 X0.0177 in)
0.020 X0.055 mm (0.0008 X0.0022 in)
1.50 2.25 mm (0.06 0.09 in)
0.10 X0.40 mm (0.0039 X0.0158 in)
0.120 mm
(0.0047 in)
SSS
SSS
17.043 mm
(0.6710 in)
SSS
SSS
16.971 mm
(0.6682 in)
0.072 mm
(0.0028 in)
SSS
SSS
0.50 mm
(0.0197 in)
0.115 mm
(0.0045 in)
SSS
SSS
0.80 mm
(0.0315 in)
0.115 mm
(0.0045 in)
SSS
SSS
8

2-8
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
0.034 X0.058 mm (0.0013 X0.0023 in)
1 = Blue 2 = Black 3 = Brown 4 = Green
0.09 mm
(0.0035 in)
SSS
Crankshaft
Width A
Width B
Max. runout C
Big end side clearance D
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
Bearing color code
55.20 X56.60 mm (2.17 X2.23 in)
298.8 X300.7 mm (11.76 X11.84 in)
SSS
0.160 X0.262 mm (0.0063 X0.0103 in)
0.014 X0.037 mm (0.0006 X0.0015 in)
0 = White 1 = Blue 2 = Black
3 = Brown 4 = Green
SSS
SSS
0.03 mm
(0.0012 in)
SSS
0.10 mm
(0.0039 in)
SSS
9

2-9
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end
of the clutch lever)
Friction plates
Color code
Thickness
Plate quantity
Color code
Thickness
Plate quantity
Color code
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
Wet, multiple disc
Outer pull, rack and pinion pull
Cable operation
Left-hand operation
10 X15 mm (0.39 X0.59 in)
Purple
2.9 X3.1 mm (0.114 X0.122 in)
7
Green
2.9 X3.1 mm (0.114 X0.112 in)
1
–
2.9 X3.1 mm (0.114 X0.112 in)
1
1.9 X2.1 mm (0.07 X0.08 in)
8
SSS
52.5 mm (2.07 in)
6
SSS
SSS
SSS
SSS
SSS
SSS
2.8 mm
(0.110 in)
SSS
SSS
2.8 mm
(0.110 in)
SSS
SSS
2.8 mm
(0.110 in)
SSS
SSS
SSS
0.1 mm
(0.0039 in)
49.9 mm
(1.96 in)
SSS
10

2-10
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
Constant mesh, 6-speed
Spur gear
65/43 (1.512)
Chain drive
45/17 (2.647)
Left-foot operation
38/15 (2.533)
33/16 (2.063)
37/21 (1.762)
35/23 (1.522)
30/22 (1.364)
33/26 (1.269)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
0.08 mm
(0.0032 in)
0.08 mm
(0.0032 in)
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Shift drum/Guide bar
SSS
SSS
0.10 mm
(0.0039 in)
Air filter type Oil coated paper element SSS
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
5PW (DENSO)
294 kPa (2.94 kg/cm2, 2.94 bar, 42.6 psi)
SSS
SSS
SSS
Throttle position sensor
Resistance
Output voltage (at idle)
4.9 X5.1 kΩat 20_C (68_F)
0.63 X0.73 V
SSS
Throttle bodies
Model (manufacturer) quantity
Intake vacuum pressure
Throttle cable free
p
lay (at the flange
45EIDW (MIKUNI) 2
22 kPa (165 mmHg, 6.4966 inHg)
3X5mm(012X0 20 in)
SSS
SSS
SSS
Throttle
cable
free
lay
(at
the
flange
of the throttle grip)
ID mark
Throttle valve size
3
X
5
mm
(0
.
12
X
0
.
20
in)
5VY1 00
#100
SSS
SSS
SSS
11

2-11
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type
Caster angle
Trail
Diamond
24_
97 mm (3.82 in)
SSS
SSS
SSS
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Cast wheel
17 M/C MT3.50
Aluminum
120 mm (4.72 in)
SSS
SSS
SSS
SSS
SSS
SSS
1 mm (0.04 in)
0.5 mm (0.02 in)
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Cast wheel
17 M/C MT6.00
Aluminum
130 mm (5.12 in)
SSS
SSS
SSS
SSS
SSS
SSS
1 mm (0.04 in)
0.5 mm (0.02 in)
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 X90 kg (0 X198 lb)
90 X202 kg (198 X445 lb)
High-speed riding
Min. tire tread depth
Tubeless
120/70 ZR17 M/C (58W)
Pilot POWER C (MICHELIN)
D218FL (DUNLOP)
250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
1.6 mm (0.06 in)
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 X90 kg (0 X198 lb)
90 X202 kg (198 X445 lb)
High-speed riding
Min. tire tread depth
Tubeless
190/50 ZR17 M/C (73W)
Pilot POWER G (MICHELIN)
D218L (DUNLOP)
290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)
290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)
290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
1.6 mm (0.06 in)
12

2-12
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Front brakes
Brake type
Operation
Recommended fluid
Brake lever free play
Brake discs
Diameter thickness
Min. thickness
Max. deflection
Brake pad lining thickness (inner)
Brake pad lining thickness (outer)
Master cylinder inside diameter
Caliper cylinder inside diameter
Dual disc brake
Right hand operation
DOT 4
2.3 X11.5 mm (0.09 X0.45 in)
320 4.5 mm (12.60 0.18 in)
SSS
SSS
4.5 mm (0.18 in)
4.5 mm (0.18 in)
14 mm (0.55 in)
30.1 mm and 27 mm (1.19 in and 1.06 in)
SSS
SSS
SSS
SSS
SSS
4.0 mm
(0.16 in)
0.1 mm
(0.004 in)
0.5 mm
(0.02 in)
0.5 mm
(0.02 in)
SSS
SSS
Rear brake
Brake type
Operation
Recommended fluid
Brake pedal freeplay
Brake discs
Diameter thickness
Min. thickness
Max. deflection
Brake pad lining thickness (inner)
Brake pad lining thickness (outer)
Master cylinder inside diameter
Caliper cylinder inside diameter
Single disc brake
Right foot operation
DOT 4
4.3 X9.3 mm (0.17 X0.37 in)
220 5 mm (8.66 0.20 in)
SSS
SSS
6.0 mm (0.24 in)
6.0 mm (0.24 in)
12.7 mm (0.5 in)
31.8 mm (1.25 in)
SSS
SSS
SSS
SSS
SSS
4.5 mm
(0.18 in)
0.15 mm
(0.006 in)
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
SSS
SSS
13

2-13
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Inner tube outer diameter
Inner tube bending limit
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the outer
tube, with the outer tube fully
compressed, and without the
fork spring)
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
Telescopic fork
Coil spring/oil damper
120 mm (4.72 in)
236.5 mm (9.31 in)
100 mm (3.937 in)
222.5 mm (8.76 in)
8.83 N/mm (0.90 kg/mm, 50.42 lb/in)
0 X120 mm (0 X4.7244 in)
43 mm (1.69 in)
SSS
No
Suspension oil “01” or equivalent
0.53 L (0.47 Imp qt, 0.56 US qt)
76 mm (2.99 in)
8
4.5
1
26
10
1
25
10
1
SSS
SSS
SSS
231.8 mm
(9.13 in)
SSS
SSS
SSS
SSS
SSS
0.2 mm
(0.01 in)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
14

2-14
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Steering
Steering bearing type Angular bearing SSS
Lock to lock angle (left)
Lock to lock angle (right)
27_
27_
SSS
SSS
Rear suspension
Suspension type
Rear shock absorber assembly
type
Rear shock absorber assembly
travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air
pressure
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
Swingarm (link suspension)
Coil spring/gas-oil damper
65 mm (2.56 in)
173.5 mm (6.83 in)
163.5 mm (6.44 in)
83.4 N/mm (8.50 kg/mm, 476.21 lb/in)
0 X65 mm (0.00 X2.56 in)
No
1,200 kPa (12 kg/cm2, 12 bar, 171 psi)
1
4
9
20
17
1
20
12
1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Swingarm
Free play (at the end of the
swingarm)
Radial
Axial
SSS
SSS
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
Drive chain
Model (manufacturer)
Link quantity
Drive chain slack
Maximum ten-link section
50VA8 (DAIDO)
116
20 X25 mm (0.79 X0.98 in)
SSS
SSS
SSS
SSS
150.1 mm
(5.91 in)
15