The Yamaha SR500 Page
80-81 US and Canada Models

Please note: I scanned and typed most of this stuff, I think it is pretty accurate. I double checked most of the figures and tried to concentrate on the numbers. If you find an error or would like me to check the manual just e-mail me. Some of the listings in the manual were incorrect and I tried to correct them as I went. Keep all this in mind and use this information at your own risk.

Index:

1980 and 1981 spec's for U.S. Models
 
General Specifications Engine specifications
  • Valve, valve seat and valve guide
  • Valve springs
  • CylinderPiston
  • Piston ring
  • Big end bearing
  • Crankshaft
  • Clutch
  • Transmission
  • Shifting mechanism
  • Kick starter 
  • Compression releaser
  • Air cleaner
  • Carburetor
  • Lubrication
  • Chassis specification
  • Rear suspension
  • Fuel tank
  • Wheel
  • Bearing
  • Drive chain
  • Brake 
  • Electrical Specifications
  • Rectifier 
  • Battery
  • Lighting system
  • Horn
  • Flasher relay
  • Fuse
  • Torque specifications

    General Specifications (back to Index)
     
    1980 1981
    Model: (back to Index)
    I.B.M. No.
    Frame I.D. and starting number
    Engine I.D. and starting number

    3HI
    3HI-000101
    3HI-000101

     
    Dimensions: (back to Index)
    Overall length
    Overall width (standard)
    Overall heigth (standard)
    Wheel base
    Minimum ground clearance

    2,105 mm (82.9 in)
    835 mm (32.9 in)
    1,150 mm (45.3 in)
    1,410 mm (55.5 in)
    165 mm (6.5 in)
    Weight: (back to Index)
    Net weight

    160 kg (353 lbs)
    Performance: (back to Index)
    Climbing ability
    Minimum turning radius
    Braking distance

    30 deg
    2,400 mm (94.5 in)
    14 m (45.9 ft) at 50km/h (31 mph)

    Engine specifications (back to Index)
     
    Description: (back to Index)
    Engine type
    Engine model
    Displacement
    Bore x Stroke
    Compression Ratio
    Starting system
    Ignition system
    Lubrication system

    Air cooled 4-stroke, foward incline, single, S.O.H.C.
    2J2
    499 cc (30.45 cu. in.)
    87 x 84 mm (3.425 x 3.307 in)
    9.0 : 1
    Primary kick starter
    C.D.I.
    Dry Sump system
    Cylinder Head: (back to Index)
    Combustion chamber type
    Combustion chamber volume
    (with BP7ES or N-7Y)
    Head gasket thickness

    Dome

    62.4 cc (3.81 cu. in.)
    1.0 mm (.039 in)

    Camshaft: (back to Index)
    Cam drive type
    Camshaft bearing type (left)
    Camshaft bearing type (right)
    Cam chain type and No. of links

    Drive chain (right side drive)
    6005C3
    6005C3 (with groove)
    BF05M, 106L

    Cam dimensions: (back to Index)
    A (Cam Heigth) IN.

    A (Cam Heigth) EX.

    B (Base circle) IN.

    B (Base circle) EX.

    C (Cam lift) IN.
    C (Cam lift) EX.
    Camshaft run out limit
    Valve timing: (back to Index)
    Intake open
    Intake close
    Duration
    Exhaust open
    Exhaust close
    Exhaust duration
    Valve overlap


     
     
     
     
     

    required <allowable>
    39.23 +or- .05 mm <39.08 mm>
    (1.5445 +or- .0020 in <1.5386 in>)
    39.25 +or- .05 mm <39.10 mm>
    (1.5453 +or- .0020 in <1.5394 in>)
    32.23 +or- .05 mm <32.08 mm>
    (1.2689 +or- .0020 in <1.2630 in>)
    32.28 +or- .05 mm <32.08 mm>
    (1.2709 +or- .0020 in <1.2630 in>)
    7.23 mm (.2846 in)
    7.25 mm (.2854 in)
    <0.1 mm (.0039 in)>

    BTDC 41 deg
    ABDC 71deg
    292 deg
    BBDC 77 deg
    ATDC 35 deg
    292 deg
    76 deg

    Rocker arm and rocker shaft:(Index)
    Rocker arm bearing dia. (I.D.)

    Rocker arm shaft dia. (O.D.)

    Clearance

    required <allowable>
    12.00~12.02 mm <12.05 mm>
    (.4724~.4732 in <.4744 in>)
    11.98~11.99 mm <11.96 mm>
    (.4714~.4720 in <.4709 in>)
    .01~.04 mm <.11 mm>
    (.0004~.0016 in <.0043 in>)
    Valve, valve seat and valve guide:(Index)
    Valve clearance (cold): IN.
    Valve clearance (cold): EX.
    No. of valves per cylinder:

    Valve head dia. (A): IN. 
    Valve head dia. (A): EX. 
    Valve face width (B): IN. 
    Valve face width (B): EX. 
    Valve seat width (C): IN. 
    Valve seat width (C): EX. 
    Valve margin thickness (D): IN. 
    Valve margin thickness (D): EX. 
    Valve stem outside dia.: IN. 
    Valve stem outside dia.: EX. 
    Valve guide inside dia.: IN. 
    Valve guide inside dia.: EX. 
    Valve stem to guide clearance: IN. 

    Valve stem to guide clearance: EX.

    required <allowable>
    .10 mm (.0039 in)
    .15 mm (.0059 in)
    2 pcs
     
     
     
     
     
     
     
     
     

    47 mm (1.85 in) 
    39 mm (1.54 in) 
    2.12 mm (.0835 in) 
    2.12 mm (.0835 in) 
    1.3 mm (.051 in) 
    1.3 mm (.051 in) 
    1.3 mm (.051 in) 
    1.3 mm (.051 in) 
    7.97~7.99 mm (.3138~0.3146 in) 
    7.96~7.97 mm (.3134~0.3138 in) 
    8.01~8.02 mm (.3154~0.3157 in) 
    8.01~8.02 mm (.3154~0.3157 in) 
    .02~.04 mm <.08 mm> 
    (.0008~.0016 in <.0031 in>) 
    .04~.06 mm <.1 mm> 
    (.0016~.0024 in <.0039 in>)

    Valve springs: (back to Index)
    Free length: Inner 
    Free length: Outer
    Spring rate: Inner

    Spring rate: Outer 

    Installed length (valve closed): Inner
    Installed length (valve closed): Outer 
    Installed pressure (valve closed): Inner
    Installed pressure (valve closed): Outer 
    Compressed length (valve open): Inner
    Compressed length (valve open): Outer 
    Compressed pressure (valve open): Inner 
    Compressed pressure (valve open): Outer 
    Wire diameter: Inner
    Wire diameter: Outer
    Winding outside diameter: Inner
    Winding outside diameter: Outer
    Tilt limit from vertical: Inner
    Tilt limit from vertical: Outer

    required <allowable>
    45.3 mm <43.9 mm> (1.783 in <1.728 in>) 
    44.6 mm <43.3 mm> (1.756 in <1.703 in>) 
    K1= 1.67, K2 = 2.12 [kg/mm] 
    (K1 = 93.5, K2 = 119 [lb/in]) 
    K1 = 3.60, K2 - 4.63 [kg/mm]
    (K1 = 202, K2 = 259 [Ib/in])
    38.0 mm (1.496 in)
    40.0 mm (1.575 in) 
    12.2 kg (26.9 Ib) 
    16.4 kg (36.2 Ib)
    28.0 mm (1.102 in)
    30.0 mm (1.181 in)
    33.4 kg (73.6 Ib) 
    62.7 kg (138.2 lb)
    3.1 mm (.122 in)
    4.4 mm (0.173 in)
    23.4 mm (.921 in)
    32.9 mm (1.295 in)
    1.97 mm (.0776 in)
    1.97 mm (.0776 in)
    Cylinder: (back to Index)
    Material
    Bore size 

    Taper limit 
    Out Of round limit

    required <allowable>
    Aluminum alloy with special cast iron sleeve
    87.00 ~87.02 mm <87.1 mm> 
    (3.4252 ~3.4260 in <3.429 in>)
    <.05 mm> (<.0020 in>)
    <.01 mm> (<.0004 in>)
    Piston: (back to Index)
    Piston clearance 
    Piston clearance measuring position 
    (from piston skirt bottom) 
    Piston pin bore size

    Piston pin outside diameter

    Piston pin length 
    Over size piston diameter: 1 st 
    Over size piston diameter: 2nd 
    Over size piston diameter: 3rd 
    Over size piston diameter: 4th

    required <allowable>
    .050 ~ .055 mm (.0020 ~ .0022 in)

    7.2 mm (.283 in)
    20.00 ~ 20.02 mm <20.08 mm>
    (.7874 ~ .7882 in <.7905 in>) 
    19.99 ~ 20.00 <19.96 mm>
    (.7870 ~ .7874 in <.7858 in>) 
    75 mm (2.95 in)
    87.25 mm (3.4350 in)
    87.50 mm (3.4449 in) 
    87.75 mm (3.4547 in)
    88.00 mm (3.4646 in)

    Piston ring: (back to Index)
    Piston ring design: Top ring 
    Piston ring design: 2nd ring
    Piston ring design: Oil ring
    Ring end gap (installed): Top ring 

    Ring end gap (installed): 2nd ring

    Ring end gap (installed): Oil ring 
    Ring groove side clearance: Top ring 

    Ring groove side clearance: 2nd ring

    Ring groove side clearance: Oil ring 
    Over size piston ring: Ist 
    Over size piston ring: 2nd 
    Over size piston ring: 3rd 
    Over size piston ring: 4th 

    required <allowable>
    Plain ring
    Plain ring 
    Oil ring with expander
    .3 ~ .5 mm <0.8 mm> 
    (.012 ~ .020 in <.030 in>)
    .3 ~ .5 mm <.8 mm> 
    (.012 ~ .020 in <.031 in>)
    .2 ~ .9 mm <1.0 mm> 
    .04 ~ .08 mm <.15 mm>
    (.0016 ~ .0031 in <.0059 in>) 
    .03 ~ .07 mm <.15 mm> 
    (.0012 ~ .0028 in <.0059 in>)
    N.A.
    87.25 mm (3.4350 in)
    87.50 mm (3.4449 in)
    87.75 mm (3.4547 in)
    88.00 mm (3.4646 in)
    Big end bearing: (back to Index)
    Type 
    Inside dia. x outside dia. x width 
    Needle dia. x quality 

    Needle bearing
    34 x 42 x 24 mm (1.34 x 1.65 x .94 in)
    IKO 4 mm (.16 in) x 18 pcs
    KOYO 4 mm (.16 in) x 17 pcs.
    Crankshaft: (back to Index)
    Crankshaft assembly width (F)
    Crankshaft deflection ( D )
    Connecting rod large end side clearance (C) 
    Connecting rod small end deflection (P) 

    Crank pin outside dia. x length 
    Crank bearing type; Left 
    Crank bearing type; Right 
    Crank oil seal type: Left 
    Crank oil seal type: Right 
    required <allowable>
    74.95 ~ 75.00 mm (2.9508 ~ 2.9528 in)
    <.03 mm (.0012 in) or less>
    .35 ~ .65 mm (.0138 ~ .0256 in)
    .8 ~ 1.0 mm <2.0 mm>
    (.0315 ~ .0394 in <0.079 in>)
     
     
     
     
     
     
     

    34 x 74 mm (1.34 x 2.91 in)
    6306 SH2-9-C4
    6307 SH2-9-C4 with special heat treatment
    SD-30-60-6
    S-14-25-5.5 special

    Clutch: (back to Index)
    Clutch type 
    Clutch push mechanism 
    Primary reduction ratio and method 
    Primary reduction gear back lash number 
    Primary drive gear back lash number 
    Primary driven gear back lash number 
    Friction plate: Thickness/quantity 

    Clutch plate: Thickness/quantity 
    Clutch plate: Warp limit
    Clutch spring: Free length/quantity 

    Clutch spring: Spring set weight 
    Clutch spring: Spring constant 
    Clutch housing thrust clearance 
    Push rod bending limit 
    Push lever axle: Bearing type and size 
    Push lever axle: Oil seal type and size 

    required <allowable>
    Wet, multiple disc type
    Inner push, cam axle type
    77/30 (2.566), spur gear
    148 ~ 150
    21.79 +0 -.04 mm (4 Teeth)
    52.71 +0 -.04 mm (9 Teeth) 
    2.8 mm <2.5 mm> /8 pcs.
    (.110 in <.098 in> /8 pcs.)
    1.2 mm /7 pcs. (.047 in /7 pcs.)
    <.05 mm (.0020 in)>
    41.2 mm <40.0 mm> /6 pcs.
    (1.622 in <1.575 in> /6 pcs.)
    19.8 x 6 kg/25 mm (43.7 6 lb/.984 in)
    1.22 kg/mm (68.3 lb/in)
    .10 ~ .21 mm (.004 ~ .008 in)
    <.2 mm (.0079 in) or less>
    Needle bearing (17-21.5-15) x 2 pcs.
    SD-17-28-6
    Transmission: (back to Index)
    Type 
    Gear ratio: 1st
    Gear ratio: 2nd 
    Gear ratio: 3rd 
    Gear ratio: 4th 
    Gear ratio: 5th 
    Bearing type: Main axle (Left) 
    Bearing type: Main axle (Right) 
    Drive axle (Left) 
    Drive axle (Right) 
    Drive axle (Left) 
    Secondary reduction ratio and method

    Constant mesh. 5 speed
    33/14 (2.357)
    28/18 (1.555)
    25/21(1.190) 
    22/24 (0.916)
    21/27 (0.777)
    Needle bearing (20-32-12) 
    4205 
    6305 special
    Needle bearing (20-36-12) 
    SD-35-62-10
    44/16 (2.750), chain
    Shifting mechanism: (back to Index)
    Operation system 
    Shifting type 
    Oil seal type: Change lever

    Return type, left foot operation 
    Guide bar type, cam drum system 
    SDO-14-24-6
    Kick starter: (back to Index)
    Type 
    Oil seal type Kick axle

    Ratchet type 
    SD-25-35-7
    Compression releaser: (back to Index)
    Type 
    Lever free play 
    Oil seal type

    Manual, wire linked cam axle type 
    2 mm (.079 in) 
    SD-12-17-2.5-2NR
    Air cleaner: (back to Index)
    Type/quantity

    Dry foam rubber / l pc.
    Carburetor: (back to Index)
    Type and manufacture/quantity I
    I.D. mark 
    Main jet (M.J.) 
    Airjet (A.J.) 
    Jet needle: Clip position (J.N.) 
    Needle jet (N.J.) 
    Cutaway (C.A.) 
    Pilot jet (P.J.)
    Mixture screw turns out 
    Starter jet(G.S.) 
    Float hight
    Idling engine speed

    VM32SS MIKUNI / I pc. 
    3H100
    #260
    #45 
    5FL31
    P-8
    3.5
    #20
    Preset
    #50
    23.5 +or- .5 mm (.925 +or- .020 in)
    1100 r/min
    Lubrication: (back to Index)
    Transmission gear and engine sump oil 
    Quantity
     

    Type engine oil
    Oil pump: Type 
    Oil pump: Housing inside diameter

    Oil pump: Housing depth (delivery)

    Oil pump: Housing depth (scavenger)

    Oil pump: Rotor diameter

    Oil pump: Rotor thickness (delivery)
    Rotor thickness (scravenger) 
    Outer rotor and housing clearance

    Side clearance

    Tip clearance

    Check valve opening pressure 
    By-pass valve opening pressure 
    Oil cleaner type

    required <allowable>
    Total amount: 2.4 lit (2.5 US.qt)(2.11 IMP.qt)
    Periodic oil charge: 2.0 lit (2.1 US.qt)(1.76 IMP.qt)
    Exchange with oil fjlter: 2.1 lit (2.2 US.qt)(1.85 IMP.qt) 
    Yamalube 20W / 40 motor oil or equivalent 
    Trochoid pump 
    40.65 ~ 40.68 mm <40.85>
    (1.6004 ~ 1.6016 <1.6083 in>)
    4.03 ~ 4.06 mm <4.09 mm>
    (.1587 ~ .1598 in <.1610 in>) 
    18.03 ~ 18.06 mm <18.09 mm> 
    (.7098 ~ .7118 in <0.7122 in>) 
    40.53 ~ 40.56 mm <40.50 m>
    (1.5957 ~ 1.5968 in <1.5945 in>) 
    3.98 ~ 4.00 mm <3.95 mm>
    (.1567 ~ .1575 in <.1555 in>)
    17.98 ~ 18.00 mm <17.95 mm>) 
    .09 ~ .15 mm <.35 mm> 
    (.0035 ~ .0059 in <.0138 in>)
    .03 ~ .08 mm <0.14 mm> 
    (.0012 ~ .0031 in <.0055 in>) 
    .07 ~ .12 mm <.35 mm> 
    (.0028 ~ .0047 in <.00138 in>) 
    .18 kg/cm2 (2.56 lb/in2) 
    1.0 kg/cm2 (14.2 lb/in2) 
    Paper type

    Chassis specification (back to Index)
     
    Frame: (back to Index)
    Frame design

    Tubular steel semi double cradle
    Steering system: (back to Index)
    Caster 
    Trail 
    Number and size of balls in steering head: 
    Upper race 
    Lower race
    Lock to lock angle

    27.5 deg (62.5 deg)
    117 mm (4.6 in)

    22 pcs. 3/16 in
    19 pcs. 1/4 in
    L.R. 41.5 deg

    Front suspension: (back to Index)
    Type 
    Front fork cushion travel

    Front fork spring: 
    Free length 
    Set length 
    Wire dia. x winding dia. 
    Spring constant
     
     

    Inner tube outside diameter 
    Oil seal type 
    Front fork oil: Quantity 
    Front fork oil: Type


    Telescopic forks
    150 mm (5.9 in) 
     

    445 mm (17.52 in) 
    417 mm (16.42 in)
    3.6 x 24.3 mm (.14 x 0.96 in)
    K1 = .4 kg/mm (0 ~ 100 mm) 
    (22.4 lb/in (0 ~ 3.94 in)
    K2 = .504 kg/mm (100 ~ 150 mm) 
    (28.2 lb/in (3.94 ~ 5.91 in) 
    35 mm (1.38 in)
    SD-35-48-10.5
    182 cc (6.15 oz)(6.41 IMP.oz) 
    Yamaha fork oil 10 Wt. or equivalent

    Rear suspension: (back to Index)
    Type 
    Damper type 
    Rear shock absorber travel 
    Rear wheel travel 
    Rear shock absorber spring: 
    Free length 
    Set length (soft position) 
    Wire dia. x winding dia. 
    Spring constant
     
     

    Swing arm free play (limit) 
    Pivotshaft: 
    Outside dia. 
    Bearing type and size
    Dust seal type

    required <allowable>
    Swing arm 
    Coil spring, oil damper 
    80 mm (3.15 in)
    110 mm (4.33 in)

    216.5 mm (8.52 in) 
    198 mm (7.80 in) 
    7.5 x 61 mm (.30 x 2.40 in) 
    K1 = 1.8 kg/mm (O ~ 50 mm) 
    (100.8 lb/in (0 ~1.97 in)
    K2 = 2.1 kg/mm (50 ~ 80 mm) 
    (117.6 lb/in (1.97 ~ 3.15 in)
    <1 mm (0.039 in)> 
    16 mm (0.63 in)
    L.R. Needle bearing (22-29-20) 
    L.R. Thrust needle bearing (22-40.15-6) 
    L.R. OSO-35-41.5-8

    Fuel tank: (back to Index)
    Capacity 
    Fuel grade

    12 lit (3.2 US.Gal)(2.6 IMP.gal) 
    Regular gasoline
    Wheel: (back to Index)
    Type 
    Tire size and pattern: Front 
    Tire size and pattern: Rear 
    Rim type: Front 
    Rim type: Rear 
    Rim runout (limit): Front/Rear 
    Rim hopping (limit): Front/Rear 
    Bearing type: (back to Index)
    Front wheel (Left) 
    Front wheel (Right) 
    Rear wheel (Left)
    Rear wheel (Right) 
    Oil seat type: 
    Front wheel ( Left) 
    Front wheel (Right) 
    Meter gear 
    Rear wheel (Left) 
    Rear wheel (Right) 
    Secondary drive chain: (back to Index)
    Type 
    Number of links 
    Chain pitch 
    Chain free play
    required <allowable>
    Casting wheel 
    3.50-S19-4PR. lug type 
    4.00-S18-4PR. lug type 
    1.85-19 / Aluminum 
    2.15-18 / Aluminum
    <2 mm> (<.08 in>) 
    <2 mm> (<.08 in>)

    6303ZZ 
    6303Z
    6203RS 
    6303ZZ

    ..................
    SD-28-47-7-1 
    SDD-45-56-6 
    SD-25-40-8 
    SD-28-47-7-1

    DID 50 HDSS 
    103L +Joint 
    15.875 rnm (.6250 in) 
    20 mm (0.79 in)

    Brake (Front and rear): (back to Index)
    Type 
    Disc size (Outside die. thickness) 
    Front 
    Disc wear/limit 
    Disc pad thickness 
    Pad wear limit (Minimum thickness) 
    Master cylinder inside dia. 
    Caliper cylinder inside dia. 
    Brake fluid type 

    Rear
    Type
    Brake drum inner dia.
    Shoe dia. x width
    Lining thickness

    required <allowable>
    Hydraulic disc type 

    298 x 5 mm (11.73 x .02 in) 
    <4.5 mm> (<.18 in>)
    11 mm (.43 in) 
    <6 mm> (<.24 in>)
    14.0 mm (.55 in) 
    38.18 mm (1.50 in)
    DOT #3 brake fluid 
     

    Drum brake (Leading trailing)
    150 mm (5.9 in.)
    4 mm (.16 in) <2 mm> (<.08 in>)

    Electrical Specifications (back to Index)
     
    Voltage (back to Index) 12V
    Ignition system: (back to Index)
    C.D.I. 
    Model/Manufacturer 
    Pulser coil resistance 
    High speed (White/Red-Black) 
    Low speed (White/Green-Black) 
    Charge coil resistance 
    High speed (Red-Brown) 
    Low speed (Brown-Black) 
    Ignition timing: 
    Ignition advancer: 
    Advance type 
    Advance angle 
    Advance starting engine speed 
    Full advance engine speed 
    Ignition coil: (back to Index)
    Model/manufacturer 
    Spark gap 
    Primary winding resistance 
    Secondary winding resistance 
    Spark plug: (back to Index)
    Type 
    Spark plug gap 
    C. D.I. unit: 
    Model/Manufacturer
    required <allowable>

    032000-077 / NIPPON DENSO 

    16 ohm +or- 30% at 20 deg C(68 deg F)
    87 ohm +or-30% at 20 degC (68 deg F)

    334 ohm +or- 30% at 20degC(68 deg F) 
    329 ohm +or- 30% at 20 deg C (68 deg F)
    BTDC 12 deg / 1100 r/min

    Electrical 
    21.5 deg
    1,950 r/min 
    6,000 r/min

    029700-468 / NIPPON DENSO
    <6 mm (.24 in) / 500 r/min>
    .98 ohm +or- 20% at 20 deg C (68 deg F) 
    12k ohm +or- 20% at 20 deg C (68 deg F)

    BP-6ES (N.G.K.) or W20EP (ND)
    .7 ~ .8 mm (.028 ~ .031 in)

    070000-051/NIPPON DENSO

    Charging system: (back to Index)
    AC. magneto: 
    Model/Manufacturer 
    Rotor puller thread size 
    Output 
    Stater coil resistance 
    White-Yellow 
    White-White 
    Rectifier with regulator: (back to Index)
    Model/Manufacturer 
    (Rectifier) 
    Type 
    Capacity 
    Withstand voltage 
    (Regulator) 
    Type 
    Regulating voltage
    Allowable amperage 
    Battery: (back to Index)
    Model/Manufacturer
    Capacity 
    Charging rate 
    Specific gravity

    032000-077 / NIPPON DENSO 
    M27 x P 1.0 
    14.5V-11A / 5000 r/min

    .73 ohm +or- 30% at 20 deg C (68 deg F) 
    .80 ohm +or- 30% at 20deg C (68 deg F) 

    SH235 / SHINDENGEN

    I.C. type. three phase full wave 
    15A 
    200V

    I.C. type 
    14.5 +or- .5V 
    15A

    12N7-3B / G.S.
    12V, 7AH 
    .7A x 10 hours 
    1.280

    Lighting system: (back to Index)
    Headlight type: 
    Bulb wattage/Quantity: 
    Headlight
    Taillight 
    Brake light 
    Flasher light 
    Turn indicator light 
    Meter light 
    High beam indicator light 
    Neutral indicator light

    Sealed beam 

    12V, 50W/40W x 1
    12V 8W (3CP) x 1 
    12V 27W (32CP)x 1 
    12V 27W (32CP) x 4 
    12V 3.4W x 1 
    12V 3.4W x 4 
    12V 3.4W x 1 
    12V 3.4W x 1

    Horn: (back to Index)
    Model/Manufacturer 
    Winding resistance 
    Amperage 
    Flasher relay: (back to Index)
    Type 
    Model/Manufacturer 
    Flasher frequency 
    Capacity

    CF-12 / NIKKO HORN 
    1.24 ohm +or- 10% at 20 deg C (68 deg F) 
    2.5A

    Condenser type 
    FN257C / NIPPON DENSO 
    85 +or- 10 cycle/min. 
    12V 27W x 2 + 3W

    Fuse:
    Rating

    20A

    Torque specifications (back to Index)
    Standard (back to Index)
     
    Nut size Shaft size Standard
    Torque 

    m-kg

    Standard
    Torgue 

    ft-lb

    10 mm 6 mm 1.0 7
    12 mm 8 mm 2.0 14.5
    14 mm 10 mm 4.0 29
    17 mm 12 mm 4.5 33
    19 mm 14 mm 5.0 36
    22 mm 16 mm 6.5 47
    24 mm 18 mm 7.0 50
    27 mm 20 mm 8.0 58
    Part to be tightened Thread dia. and part name Tightening torque
    Engine: (back to Index)

    tightening sequence for head bolts

    1~5 (10mm nuts) 

    6, 7 &10 (8mm nuts)

    8, 9, 11 &12 (6mm bolts)

    3.8 m-kg (27.5 ft-lb) 

    2.0 m-kg (14.5 ft-lb)

    1.0 m-kg ( 7.0 ft-lb)

    Cylinder head and cylinder head cover
     
     

    Cylinder head
     

    Cylinder head cover
    Cylinder head side cover
    Spark plug
    Cylinder
     

    Flywheel
    Stater coil
    Valve clearance adjusting nut
    Cam sprocket
    Cam chain tensioner adjustment
    Cam chain tensioner cover
    Pump cover
    Strainer cover
    Drain plug
    Filter cover

    Delivery pipe
    Oil hose
    Exhaust pipe

    Crankcase 1 and 2
    Kick crank boss
    Clutch spring
    Primary drive gear
    Clutch boss
    Drive sprocket
    Change pedal

    10 mm stud bolt 
    10 mm nut 
    8 mm stud bolt 
    8 mm nut
    10 mm stud bolt 
    10 mm nut 
    6 mm bolt
    6 mm bolt
    6 mm bolt
    14 mm
    10 mm stud bolt 
    10 mm nut 
    6 mm bolt
    12 mm nut
    6 mm pan head screw
    8 mm nut
    10 mm bolt
    18 mm nut
    30 mm cap
    6 mm pan head screw 
    6 mm bolt
    14 mm bolt
    6 mm bolt
    5 mm bleeder screw
    8 mm union bolt
    14 mm union nut
    8 mm stud bolt
    8 mm nut
    6 mm bolt
    8 mm bolt
    6 mm screw
    16 mm nut
    18 mm nut
    18 mm nut
    6 mm bolt
    2.0 m-kg (14.5 ft-lb) 
    3.8 m-kg (27.5 ft-lb)
    1.3 m-kg ( 9.5 ft-lb) 
    2.0 m-kg (14.5 ft-lb)
    2.0 m-kg (14.5 ft-lb) 
    3.8 m-kg (27.5 ft-lb) 
    1.0 m-kg ( 7.0 ft-lb)
    1.0 m-kg ( 7.0 ft-lb)
    1.0 m-kg ( 7.0 ft-lb)
    2.0 m-kg (14.5 ft-lb)
    2.0 m-kg (14.5 ft-lb) 
    3.8 m-kg (27.5 ft-lb)
    1.0 m-kg ( 7.0 ft-lb)
    8.0 m-kg (58.0 ft-lb)
    0.9 m-kg ( 6.5 ft-lb)
    2.7 m-kg (19.5 ft-lb)
    5.0 m-kg (36.0 ft-lb) 
    4.0 m-kg (29.0 ft-lb)
    2.0 m-kg (14.5 ft-lb)
    0.7 m-kg ( 5.0 ft-lb)
    1.0 m-kg ( 7.0 ft-lb)
    3.0 m-kg (21.5 ft-lb)
    1.0 m-kg (7.0 ft-lb)
    0.5 m kg (3.5 ft-lb)
    1.8 m-kg (13.0 ft-lb)
    4.0 m-kg (29.0 ft-lb)
    1.3 m-kg ( 9.5 ft-lb)
    1.8 m-kg (13.0 ft-lb)
    1.0 m-kg ( 7.0 ft-lb)
    2.0 m-kg (14.5 ft-lb)
    0.8 m-kg ( 6.0 ft-lb)
    6.0 m-kg (43.5 ft-lb)
    6.0 m-kg (43.5 ft-lb) 
    7.0 m-kg (50.5 ft-lb) 
    0.8 m-kg (6.0 ft-lb)
    Chassis: (back to Index)
    Engine mounting bolt

    Handle crown and steering shaft
    Handle crown and handle holder
    Handle crown and inner tube
    Front fork
    Cap bolt 
    Under bracket and inner tube
    Rear cushion and frame
    Rear cushion and swing arm
    Pivot shaft
    Front wheel shaft
    Front fork and axle holder
    Engine mount stay
    Rear wheel shaft
    Sprocket wheel
    Compression bar and brake plate
    Compression bar and rear arm
    Footrest
    Net filter


    10 mm nut 
    8 mm nut
    14 mm nut
    8 mm bolt
    8 mm nut 

    30 mm bolt
    8 mm bolt
    10 mrn nut
    10 mm nut
    16 mm nut
    14 mm nut
    8 mm nut
    8 mm bolt
    16 mm nut
    8 mm nut
    10 mm nut
    12 mm nut
    8 mm nut
    22 mm bolt


    5.0 m-kg (36.0 ft-lb) 
    2.5 m-kg (18.0 ft-lb)
    5.5 m-kg (40.0 ft-lb) 
    2.0 m-kg (14.5 ft-lb)
    1.5 m-kg (11.0 ft-lb)

    2.5 m-kg (18.0 ft-lb) 
    1.5 m-kg (11.0 ft-lb)
    3.0 m-kg (21.5 ft-lb)
    3.0 m-kg (21.5 ft-lb)
    8.0 m-kg (58.0 ft-lb)
    11 m-kg (80.0 ft-lb)
    1.0 m-kg (7.0 ft-lb)
    2.0 m-kg (14.5 ft-lb)
    15 m-kg (l08 ft-lb)
    3.0 m-kg (21.5 ft-lb)
    5.0 m-kg (36.0 ft-lb)
    6.0 m-kg (43.5 ft-lb)
    0.9 m-kg ( 6.5 ft-lb)
    9.0 m-kg (65.0 ft-lb)

    Brakes: (back to Index)
    Brake disc and hub (Front) 
    Caliper bracket and front fork (Front) 
    Caliper and brake hose (Front) 
    Caliper and bleed screw (Front) 
    Master cylinder and brake hose (Front)
    Brake hose 1 and joint (Front) 

    Tension bar and brakeplate (Rear)
    Tension bar and rear arm (Rear)
    Camshaft lever and camshaft (Rear)


    8 mm bolt 
    10 mm bolt 
    10 mm bolt 
    8 mm bolt 
    10 mm bolt 
    10 mm bolt 

    8 mm nut
    8 mm nut
    6 mm nut


    2.0 m-kg (14.5 ft-lb) 
    3.5 m-kg (25.5 ft-lb) 
    2.5 m-kg (18.0 ft-lb) 
    0.6 m-kg ( 4.5 ft-lb) 
    2.5 m-kg (18.0 ft-lb) 
    2.5 m-kg (18.0 ft-lb) 

    2.0 m-kg (14.5 ft-lb)
    1.5 m-kg (11.0 ft-lb)
    0.7 m-kg ( 5 ft-lb)