Note

1. First, tighten the bolts to approximately 12 Nm (1.2 m*kg, 8.7 ft*lb) with a torque wrench.

2. Retighten the bolts 25 Nm (2.5 m*kg, 18 ft*lb) with a torque wrench.

3. Loosen the all bolts one by one following the tightening order and then tighten them to 27 Nm (2.7 m*kg, 20 ft*lb) again.

Cylinder head tightening sequence:

CHASSIS TIGHTENING TORQUES

Item

Thread size

Tightening

Remarks

Nm

m-kg

ft-lb

Upper bracket and front fork

M8

26

2.6

19

Steering stem nut

M28

113

11.3

82

Handlebar and front fork

M8

33

3.3

24

Handlebar and upper bracket

M6

13

1.3

9.4

Lower ring nut

M30

14

1.4

10

See NOTE 1

Under bracket pinch bolt

M8

23

2.3

17

Main switch and upper bracket

M8

23

2.3

17

Front brake master cylinder cap stopper

M4

1.2

0.12

0.9

Front brake hose union bolts

M10

30

3.0

22

Front brake master cylinder and bracket

M6

13

1.3

9.4

Windshield and front cowling

M5

0.4

0.04

0.3

Front cowling and headlight assembly

M5

1.7

0.17

1.23

Headlight and front cowling stay

M5

2.5

0.25

1.81

Meter assembly and front cowling stay

M5

1.3

0.13

0.94

Front cowling stay and frame

M8

23

2.3

17

Front cowling stay and duct

M5

1.3

0.13

0.94

Duct and joint

M5

1.3

0.13

0.94

Surge tank joint (front)

M4

1.2

0.12

0.87

Surge tank joint (rear)

M5

1.2

0.12

0.87

Rear view mirror and front cowling

M6

7

0.7

5.1

Cowling and inner panel

M5

1.5

0.15

1.1

Cowlings and frame

M6

4.5

0.45

3.3

Engine mount bolts (front)

M10

45

4.5

33

Engine mount bolts (rear upper)

M10

45

4.5

33

Engine mount bolts (rear lower)

M10

45

4.5

33

Engine mount adjust bolt

M16

7

0.7

5.1

Frame and rear frame

M10

47

4.7

34

Inner panel and frame

M5

3.8

0.38

2.7

Clutch cable lock nut (engine side)

M8

7

0.7

5.1

Throttle cable adjust nut (handlebar side)

M6

4.5

0.45

3.3

Pivot shaft and nut

M18

95

9.5

69

Connecting rod and frame

M10

44

4.4

32

Relay arm and connecting rod

M10

44

4.4

32

Relay arm and swingarm

M10

44

4.4

32

Rear shockabsorber and relay arm

M10

44

4.4

32

Rear shockabsorber and bracket

M10

44

4.4

32

Bracket and frame

M14

52

5.2

38

Fuel pump and fuel tank

M5

4

0.4

2.9

Fuel tank bracket and frame

M6

7

0.7

5.1

Fuel tank bracket and fuel tank

M6

7

0.7

5.1

Fuel tank and rear frame

M6

7

0.7

5.1

Rider seat and frame

M6

7

0.7

5.1

Coolant reservoir tank and generator rotor cover

M6

6.5

0.65

4.7

Footrest bracket and frame

M8

28

2.8

20

Rear footrest and frame

M8

28

2.8

20

Rear footrest and muffler

M8

23

2.3

17

Rear brake master cylinder and footrest bracket

M8

18

1.8

13

Item

Thread size

Tightening

Remarks

Nm

m*kg

ft* lb

Rear brake hose union bolt

M10

30

3.0

22

Sidestand bracket and frame

M10

61

6.1

44

Front wheel axle shaft and bolt

M14

91

9.1

66

Rear wheel axle nut

M24

110

11.0

80

Front brake caliper and front fork

M10

40

4.0

29

Front brake disc and front wheel

M6

18

1.8

13

Rear brake disc and rear wheel

M8

30

3.0

22

Rear wheel sprocket and rear wheel drive hub

M10

100

10.0

72

Brake caliper bleed screw

M8

6

0.6

4.3

Pinch bolt (front wheel axle)

M8

18

1.8

13

1. First, tighten the ring nut to approximately 52 Nm (5.2 m-kg, 38 ft-lb) with a torque wrench, then loosen the ring nut completely.

2. Retighten the lower ring nut to specification.

• Tighten wheel axle pinch bolts (2 and ® to specified torque.

• Retighten pinch bolt (2 to specified torque.

• Tap the outer side of the left fork leg with a rubber mallet to align it with the end of the wheel axle.

• Tighten wheel axle pinch bolts @ and ® to specified torque.

• Retighten pinch bolt @ to specified torque.

LUBRICATION POINTS AND LUBRICANT TYPES

spec g»

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication point

Lubricant

Oil seal lips

O-rings

Bearings

-a

Crankshaft pins

-a

Piston surfaces

-a

Piston pins

-a

Connecting rod bolts and nuts

-o

Crankshaft journals

Camshaft lobes

Camshaft journals

Valve stems (intake and exhaust)

—-O

Valve stem ends (intake and exhaust)

-a

Valve lifter surface

-a

Piston cooler (O-ring)

-a

Oil pump rotors (inner and outer)

-a

Oil pump housing

-a

Oil strainer

-a

Clutch (pull rod)

Starter clutch idle gear inner surface

-a

Starter clutch assembly

-a

Primary driven gear

-a

Transmission gears (wheel and pinion)

-o

Main axle and drive axle

Shift drum bearing

-a

Shift forks and shift fork guide bars

-a

Shift shaft

-a

Shift shaft boss

-a

Cylinder head cover mating surface

Yamaha bond No.1215

Crankcase mating surface

Yamaha bond No.1215

Generator rotor cover (stator coil assembly lead grommet)

Yamaha bond No.1215

Pickup rotor cover (crankshaft position sensor lead grommet)

Yamaha bond No.1215

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