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-Z RX
SUPPLEMENTARY SERVICE MANUAL
55K-F8197-E1
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the RXZ (2002). For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
RX-Z (2002) SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Co., Ltd. First Edition, December 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
NOTICE
This manual was written by Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and qualified mechanics. It is not possible to put an entire mechanics education into one manual, so persons using this book to perform maintenance and repairs on Yamaha motorcycles should have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to the motorcycle may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
NOTE:
A NOTE provides key information to make procedures easier or clearer. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle.
cC fWARNING:
PARTICULARLY IMPORTANT INFORMATION All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this reversed format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., 8 Bearings Pitting/Damage Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.
GEN INFO
3
INSP ADJ
4
ENG
5
COOL
6
CARB
7
CHAS
8
ELEC
9
APPX
0
Illustrated symbols 9 to r are used to identify the specifications appearing in the text.
9 Filling fluid 0 Lubricant q Tightening w Wear limit, clearance e Engine speed r , V, A
Illustrated symbols t to a in the exploded diagrams indicate the types of lubricants and lubrication points.
t Apply engine oil y Apply gear oil u Apply molybdenum disulfide oil i Apply wheel bearing grease o Apply lightweight lithium-soap base grease p Apply molybdenum disulfide grease a Apply locking agent (LOCTITE)
i
B
o
LS
p
M
a
LT
CONTENTS
GENERAL INFORMATION .......................................................................1
MOTORCYCLE IDENTIFICATION ..............................................................1 FRAME SERIAL NUMBER.....................................................................1 ENGINE SERIAL NUMBER ...................................................................1
CHASSIS ........................................................................................................6
REAR WHEEL .............................................................................................6 FRONT FORK..............................................................................................7 HANDLEBARS ............................................................................................8 INSTALLATION.......................................................................................9 STEERING HEAD......................................................................................11 REAR SHOCK ABSORBER AND SWINGARM .......................................12
APPENDICES .............................................................................................13
SPECIFICATIONS .....................................................................................13 GENERAL SPECIFICATIONS...................................................................13 MAINTENANCE SPECIFICATIONS..........................................................14 ENGINE................................................................................................14 TIGHTENING TORQUE .......................................................................15 CHASSIS..............................................................................................16 TIGHTENING TORQUE .......................................................................16 ELECTRICAL .......................................................................................17
MOTORCYCLE IDENTIFICATION
GEN INFO
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER The frame serial number 1 is stamped into the steering head pipe.
ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right rear section of the engine.
NOTE:
The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.
NOTE:
Designs and specifications are subject to change without notice.
INSP ADJ
PERIODIC MAINTENANCE/LUBRICATION
9 Check fuel hoses for cracks or damage. 9 Replace if necessary. 9 Check condition. 9 Clean, regap or replace if necessary. 9 Clean or replace if necessary. 9 Check electrolyte level and specific gravity. 9 Correct or recharge if necessary. 9 Make sure that the breather hose is properly routed. 9 Check operation. 9 Adjust or replace cable. 9 Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-5.) 9 Correct accordingly. 9 Replace brake pads if necessary. 9 Check operation. 9 Adjust cable and replace brake shoes if necessary. 9 Check balance, runout, spoke tightness and for damage. 9 Tighten spokes and rebalance, replace if necessary. 9 Check tread depth and for damage. 9 Replace if necessary. 9 Check air pressure. 9 Correct if necessary. 9 Check bearing for looseness or damage. 9 Replace if necessary. 9 Check swingarm pivoting point for play. 9 Correct if necessary. 9 Lubricate with lithium soap based grease. 9 Check chain slack. 9 Adjust if necessary. Make sure that the rear wheel is properly aligned. 9 Clean and lubricate. 9 Check bearing play and steering for roughness. 9 Correct accordingly. 9 Lubricate with lithium soap based grease every 24,000 km or 24 months (whichever comes first). 9 Make sure that all nuts, bolts and screws are properly tightened. 9 Tighten if necessary. 9 Check operation. 9 Lubricate and repair if necessary. 9 Check operation and for oil leakage. 9 Correct accordingly. 9 Check operation and shock absorbers for oil leakage. 9 Replace shock absorber assembly if necessary. 9 Check engine idling speed and starter operation. 9 Adjust if necessary. 9 Check operation. 9 Correct if necessary. 9 Bleed if necessary. 9 Check oil level and vehicle for oil leakage. 9 Correct accordingly. 9 Change oil at initial 1,000 km and thereafter every 24,000 km or 24 months (whichever comes first).
4 * Battery 5 Clutch
6 * Front brake
9 * Tires
12
Drive chain
Every 500 km and after washing the motorcycle or riding in the rain
13 * Steering bearings
20
Transmission oil
*: Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
PERIODIC MAINTENANCE/LUBRICATION
INSP ADJ
NOTE: 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Brake fluid replacement 1. When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. 2. Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. 3. Replace the brake hoses every four years or if cracked or damaged.
INSP ADJ
PERIODIC MAINTENANCE/LUBRICATION
q q
PERIODIC MAINTENANCE/LUBRICATION
1 2 ~ 3 mm (0.08 ~ 0.12 in)
INSP ADJ
1 Front = 175 kPa (1.75 kg/cm2, 25 psi) Rear = 200 kPa (2.0 kg/cm2, 28 psi)
CHAS
REAR WHEEL
1 2 3 4 5 6 7 8 9 Chain puller Stopper Cam lever Wear indicator Spacer collar Tension bar Brake lining plate Brake cam shaft Brake lining
REAR WHEEL
CHASSIS
0 q w e r t y u i Oil seal Bearing Spacer flange Bearing spacer Bearing Damper Sprocket shaft Sprocket hub Driven sprocket o p a s Drive chain Bearing Oil seal Collar
4 3
B
TIRE SIZE: 90/90 - 18 51P LINING WEAR LIMIT: 2.0 mm (0.08 in)
0 q B6202 w e
r B6202Z
LS
B6202Z p a
E F
FRONT FORK
FRONT FORK
1 2 3 4 5 6 7 Rubber cap Cap bolt O-ring Spacer Washer Fork spring Rebound spring 8 9 0 q w e r Damper rod Inner tube Oil lock piece Dust seal Retaining clip Oil seal Plate washer
CHAS
1 2 3 4 5 6
7
30 Nm (3.0 kgm,22 ftlb)
8 q w e r t 9
A B C
FORK OIL CAPACITY (EACH FORK): 165 cm3 (5.82 Imp oz, 5.78 US oz) RECOMENDED OIL: SAE 10W30 TYPE SE MOTOR OIL FORK SPRING MINIMUM LENGTH: 428.1 mm (16.9 in)
0 u
23 Nm (2.3 kgm,17 ftlb)
CHAS
HANDLEBARS
1 2 3 4 Handlebar grip end Grip rubber Leaf ring Throttle guide tube
HANDLEBARS
5 Handlebar (right) 6 Throttle and oil pump cable assembly 7 Adjuster 8 9 0 q Locknut Clutch cable Handlebar (left) Collar
4
LS
5 0 q 2
8
LS
HANDLEBARS
INSTALLATION 1. Install: 9 Handlebars
CHAS
2. 9 9 9 9
Install: Lever holder 1 (left) Handlebar grip 2 (left) Handlebar switch 3 (left) Handlebar grip end 4 (left)
Left handlebar install steps: 8Install the lever holder 1 to the handlebar.
Bolt (lever holder): 6.5 Nm (0.65 mkg, 4.7 ftlb) 8Apply a light coat of an adhesive for rubber to the handlebar. 8Fit the handlebar grip fully over the handlebar end. NOTE: Wipe off the excess adhesive with the clean rag.
:WARNING:
Leave the handlebar intact until the adhesive becomes dry enough to make the grip and handlebar stuck securely.
8Install the handlebar grip end (left). Handlebar grip end: 25 Nm (2.5 mkg, 18 ftlb) 8Install the handlebar switch (left).
CHAS
HANDLEBARS
3. 9 9 9 Install: Handlebar grip (right) Throttle cable Handlebar switch (right)
NOTE: Before installing the handlebar grip (right), apply a light coat of lithium - soap base grease onto the handlebar end.
:WARNING:
Provide the clearance of 1 mm (0.04 in) between the handlebar grip 1 and the handlebar grip end 2. Otherwise, the grip may not move. 2 1
4. Tighten: 9 Handlebar grip end (right) Handlebar grip end: 25 Nm (2.5 mkg, 18 ftlb) 9 Front brake master cylinder Bolt (master cylinder bracket): 23 Nm (2.3 mkg, 17 ftlb)
5. Install: 9 Clutch cable NOTE: Apply a light coat of lithium - soap base grease onto the clutch cable end.
10
STEERING HEAD
STEERING HEAD
1 2 3 4 5 6 7 Stem nut Handle crown Ring nut Ball race cover Ball race (lower - top) Balls Ball race (upper - bottom) 8 9 0 q Ball race (lower - top) Balls Ball race (lower - bottom) Under bracket
CHAS
3 4
LS
5 6 7 8 9
LS
11
CHAS
1 2 3 4 5 Chain adjuster Chain adjuster Chain guard Shock absorber Swingarm
A SWING ARM FREE PLAY LIMIT: B END: 1.0 mm (0.04 in) C SIDE: 1.0 mm (0.04 in)
4
LS LS
7 8
9 6
LS
0
LS
8 7 6
12
SPECIFICATIONS
APPX
APPENDICES
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model Model Code Number: Frame and Engine Starting Serial Number: Dimensions: Overall Length Overall Width Overall Height Seat Height Wheelbase Minimum Ground Clearance Basic weight: With Oil and Full Fuel Tank Spark plug: Type/Manufacturer Gap Transmission: Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type Operation Gear Ratio 1st 2nd 3nd 4th 5th 6th Electrical: Ignition System Generator System Battery Type or Model Battery Capacity Bulb Wattage/Quantity: Headlight Tail/Brake Light Flasher Light Meter Light 5PV 5PV-000101 1,990 mm (78.3 in) 725 mm (28.5 in) 1,160 mm (45.7 in) 770 mm (30.3 in) 1,300 mm (51.2 in) 175 mm ( 6.9 in) 118 kg (261 lb) BR9ES/NGK 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Herical gear 71/22 (3.227) Chain drive 46/16 (2.875) Constant mesh, 6-Speed Left foot operation 34/12 (2.833) 29/16 (1.813) 26/19 (1.368) 24/21 (1.143) 23/23 (1.000) 22/24 (0.917) C.D.I. A.C. Magneto YB3L-B 12V, 3AH 12V 35W/30W x 1 12V 5W/21W x 1 12V 10W x 4 12V 1.7W x 3 RX-Z
13
APPX
SPECIFICATIONS
Model RX-Z 14V 3W x 1 14V 3W x 1 14V 3W x 1 14V 3W x 1
MAINTENANCE SPECIFICATIONS
ENGINE
Model Piston: Piston size D/Measuring Point H RX-Z 55.964 ~ 55.986 mm (2.203 ~ 2.204 in)/ 10 mm (0.41 in) 0.034 ~ 0.036 mm (0.00134 ~ 0.00142 in)
Piston Clearance
Piston Offset Carburtor: Type/Manufacturer/Quantity I.D. Mark Main Jet (M.J.) Main Air Jet (M.A.J.) Jet Needle-clip position (J.N.) Needle Jet (N.J.) Pilot Jet (P.J.) Pilot Air Screw (P.A.S.) Float Height (F.H.) Fuel Level (F.L.) Engine Idling Speed Reed Valve: Thickness* Valve Stopper Height Valve Bending Limit
0.5 mm (0.02 in) IN side VM26SS/MIKUNI/1 5PV1 00 # 195 0.5 5FHE5-2 O-8M # 22.5 1 and 1/4 21.0 1.0mm (0.2 in) 0.5 mm (0.02 in) (above the carburetor body edge) 1,250 ~ 1,350 r/min 0.42 mm (0.017 in) 10.0 ~ 10.6 mm (0.39 ~ 0.42 in) 0.8 mm (0.031 in)
14
SPECIFICATIONS
Model Lubrication System: Autolube Pump: Color Code Minimum Stroke Maximum Stroke Minimum Output/200 Stroke Maximum Output/200 Stroke Adjusting mark (at idle) RX-Z
APPX
White 0.30 ~ 0.35 mm (0.012 ~ 0.014 in) 1.85 ~ 2.05 mm (0.073 ~ 0.081 in) 0.76 ~ 0.90 cm3 (0.027 ~ 0.032 Imp oz, 0.062 ~ 0.030 US oz) 4.65 ~ 5.15 cm3 (0.163 ~ 0.180 Imp oz, 0.158 ~ 0.175 US oz) Square Mark
TIGHTENING TORQUE
Part to be Tightened Spark Plug Reed Valve Exhaust Pipe Drain Plug Push Rod #1 Bearing Cover Plate Tachometer Housing Stopper Lever C.D.I. Magneto Part Name Tightening Torque Thread Q'ty Size Nm mkg ftlb M14 M6 M8 M12 M6 M6 M6 M6 M12 1 4 2 2 1 2 1 1 1 25 10 7 20 7 7 5 10 83 2.5 1.0 0.7 2.0 0.7 0.7 0.5 1.0 8.3 18 7.2 5.1 14 5.1 5.1 3.6 7.2 60 Remarks
15
APPX
CHASSIS
SPECIFICATIONS
Model Front Suspension: Front Fork Travel Front Spring Free Length <Limit> Spring rate/Stroke
RX-Z 140 mm (5.51 in) 432.4 mm (17.0 in) <428.1 mm (16.9 in)> K1 = 7.4 N/mm (0.75 kg/mm, 42.0 lb/in) 0 ~ 120 mm (0 ~ 4.72 in) K2 = 10.8 N/mm (1.1 kg/mm, 61.6 lb/in) 120~155 mm (4.72 ~ 6.1 in) No 165 cm3 (5.82 Imp oz, 5.78 US oz) 165 mm (6.5 in) (From top of inner tube fully compressed without spring) Fork oil 10W or equivalent
Oil Grade
TIGHTENING TORQUE
Tightening Torque Part to be Tightened Engine Mounting: Front Rear Rear Arm and Frame Handle Crown and Inner Tube Under Bracket and Inner Tube Master Cylinder and Brake Hose Brake Hose and Brake Caliper Footrest Bracket and Frame Footrest Bracket and Rear Bracket Front Hub and Front Disk Handle Crown and Main Switch Handlebar and Inner Tube Handlebar and Handle Crown End Grip and Handlebar Side Stand and Frame: Bolt Nut Thread Size Q'ty Nm mkg ftlb M8 M8 M12 M8 M8 M10 M10 M10 M10 M8 M6 M8 M6 M16 M10 M10 1 1 1 4 4 1 1 4 2 4 2 2 2 2 1 1 30 25 43 25 30 26 26 43 43 23 13 20 9 25 23 40 3.0 2.5 4.3 2.5 3.0 2.6 2.6 4.3 4.3 2.3 1.3 2.0 0.9 2.5 2.3 4.0 22 18 31 18 22 19 19 31 31 17 10 14 6.5 18 17 29 Remarks
16
SPECIFICATIONS
ELECTRICAL
Model Ignition System: Ignition Timing (B.T.D.C.) Advancer Type C.D.I.: Magneto-Model/Manufacturer Pickup Coil Resistance/Color Source Coil Resistance/Color C.D.I. Unit-Model/Manufacturer Ignition coil: Model/Manufacturer Minimum Spark Gap Primary Winding Resistance Secondary Winding Resistance Charging System: Type Charging Current 14 at 1,500 r/min Digital RX-Z
APPX
F5PV/YAMAHA 310 10 % at 20C (68F) / W/L - W/R 860 10 % at 20C (68F) / G/W - B/R 5PV/YAMAHA 4BE/YAMAHA 6mm (0.24 in) at 1,300 r/min 0.23 20 % at 20C (68F) 7.9 k 20 % at 20C (68F) C.D.I. Magneto
17
APPX
SPECIFICATIONS
Model RX-Z SH671 - 12/SHINDENGEN 14.0~15.0 V Less than 13.3 V 8A 12 A 12 V, 3 AH 1.260 Plain type/1 5PV/NIKKO 5A 3FY/STANLEY Fuse 7Ax1 7Ax1
Rectifier Regulator: Model/Manufacture No Load Regulated Voltage Capacity Battery: Capacity Specific Gravity Horn: Type/Quantity Model/Manufacturer Maximum Amperage Oil Level Switch: Model/Manufacturer Circuit Breaker: Type Amperage for Individual/Quantity Main Reserve
18
1
B/W LOCK OFF ON
B/R G/W
Or
W/R
B/W W/L
Br B R
B/W
B Br R
B/W B/W
Sb W B Y/R
W Sb Y/R B
q
Or W/L W/R G/W B/R W/L W/R G/W B/R R W B R Y/R W W Y/R
Br R B R
B B B
7
B
Y/R
2
R
B/W
5 6 3
RUN OFF
A B Sb
9
P Br P Br
MAIN HARNESS
SUB HARNESS
4
Br
s
Dg Ch Dg Ch
Br
Br A Br
y
Br P Br/W Br
t
Br Br
G B L
Sb B/R Br
Sb B/R Br
G B L
j k
Sb B/R
g h
f
Ch Dg
u i
HI LO Y Y G
L L
Y/R
P A P
Br/W
o
OFF ON
p
OFF PUSH
a
L N R
Br
r
G/Y B
Ch Dg Ch
Dg Dg Ch
L G/Y G/Y G/Y
Main switch Fuse Battery Ground lead Handlebar switch (right) Engine stop switch Rectifier/Regulator C.D.I. Magneto Neutral switch C.D.I. Unit Ignition coil Spark plug Rear brake switch Front brake switch Turn signal relay Horn Handlebar switch (left) LIGHTS dimmer switch PASS switch HORN switch TURN signal switch Meter assy TURN signal indicator light HI BEAM indicator light Meter light FUEL meter OIL warning indicator light NEUTRAL indicator light Fuel sender Oil level gauge Tail/Brake light Rear turn signal light (right) Rear turn signal light (left) Front turn signal light (left) Front turn signal light (right) Sub lead wire Headlight
;
Y G Sb Sb Y G B B B Y G B
Y G
Dg
Ch
B Ch Dg Y G Ch B Dg G Y
Y B L G/Y Dg L G/Y Dg B
Ch
Ch
B Sb B/R
B Sb B/R
n
B
cx
B
Dg
Ch
COLOR CODE
B...................Black Br .................Brown Ch ................Chocolate Dg ................Dark green G ..................Green L ...................Blue O ..................Orange P...................Pink R ..................Red Sb.................Sky blue W..................White Y...................Yellow B/R ...............Black/Red B/W ..............Black/White Br/W .............Brown/White G/W..............Green/White G/Y...............Green/Yellow W/L...............White/Blue W/R ..............White/Red Y/R ...............Yellow/Red