Professional Documents
Culture Documents
RX Z
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:
cC
fWARNING:
ILLUSTRATED SYMBOLS
(Refer to the illustration)
GEN
INFO
INSP
ADJ
ENG
1
2
3
4
5
6
7
8
COOL
CARB
CHAS
ELEC
APPX
p
LS
a
LT
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
General information
Periodic inspection and adjustment
Engine
Cooling system
Carburetion
Chassis
Electrical
Appendices
Illustrated symbols t to a in the exploded diagrams indicate the types of lubricants and lubrication points.
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.
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
ITEM
1 * Fuel line
Spark plug
9 Check condition.
9 Clean, regap or replace if necessary.
Air filter
Initial
(1,000 km)
6,000 km
or
6 months
(Whichever
comes first)
12,000 km
or
12 months
(Whichever
comes first)
4 * Battery
9 Check operation.
9 Adjust or replace cable.
6 * Front brake
7 * Rear brake
9 Check operation.
9 Adjust cable and replace brake shoes if necessary.
8 * Wheels
9 * Tires
10 * Wheel bearings
11 * Swingarm
12
Drive chain
13 * Steering bearings
14 * Chassis fasteners
9 Make sure that all nuts, bolts and screws are properly
tightened.
9 Tighten if necessary.
15
9 Check operation.
9 Lubricate and repair if necessary.
Clutch
Sidestand/centerstand
16 * Front fork
17 *
18 * Carburetor
19 * Autolube pump
9 Check operation.
9 Correct if necessary.
9 Bleed if necessary.
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
INSP
ADJ
CHAS
REAR WHEEL
CHASSIS
REAR WHEEL
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
i
Chain puller
Stopper
Cam lever
Wear indicator
Spacer collar
Tension bar
Brake lining plate
Brake cam shaft
Brake lining
o
p
a
s
Oil seal
Bearing
Spacer flange
Bearing spacer
Bearing
Damper
Sprocket shaft
Sprocket hub
Driven sprocket
Drive chain
Bearing
Oil seal
Collar
TIRE SIZE:
90/90 - 18 51P
2
1
D
LS
LS
0
q
B6202 w e
r
B6202Z
LS
B6202Z
p
a
FRONT FORK
CHAS
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
t Slide metal
y Outer tube
u Damper rod bolt
Damper rod
Inner tube
Oil lock piece
Dust seal
Retaining clip
Oil seal
Plate washer
1
2
3
4
5
6
7
8
q
w
e
r
t
9
RECOMENDED OIL:
SAE 10W30 TYPE SE MOTOR OIL
0
u
23 Nm (2.3 kgm,17 ftlb)
CHAS
HANDLEBARS
HANDLEBARS
1
2
3
4
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
CHAS
INSTALLATION
1. Install:
9 Handlebars
2.
9
9
9
9
Install:
Lever holder 1 (left)
Handlebar grip 2 (left)
Handlebar switch 3 (left)
Handlebar grip end 4 (left)
: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.
6. Adjust:
9 Clutch cable free play
Refer to the CLUTCH ADJUSTMENT.
10
CHAS
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
3
4
LS
5
6
7
8
9
LS
11
CHAS
6
7
8
9
0
Chain adjuster
Chain adjuster
Chain guard
Shock absorber
Swingarm
Thrust cover
Bearing
Collar
Oil seal
Nipple
4
5
LS
LS
7 8
9
6
LS
0
LS
7
6
12
SPECIFICATIONS
APPX
APPENDICES
SPECIFICATIONS
GENERAL SPECIFICATIONS
RX-Z
Model
Model Code Number:
5PV
5PV-000101
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
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)
Electrical:
Ignition System
Generator System
Battery Type or Model
Battery Capacity
C.D.I.
A.C. Magneto
YB3L-B
12V, 3AH
Bulb Wattage/Quantity:
Headlight
Tail/Brake Light
Flasher Light
Meter Light
12V 35W/30W x 1
12V 5W/21W x 1
12V 10W x 4
12V 1.7W x 3
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
RX-Z
Model
Piston:
Piston size D/Measuring Point H
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
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
Reed Valve:
Thickness*
Valve Stopper Height
Valve Bending Limit
14
APPX
SPECIFICATIONS
RX-Z
Model
Lubrication System:
Autolube Pump:
Color Code
Minimum Stroke
Maximum Stroke
Minimum Output/200 Stroke
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
Bolt
Stud bolt
Bolt
Nut
Screw
Bolt
Bolt
Nut
Tightening Torque
Thread
Q'ty
Size
Nm mkg ftlb
M14
M6
M8
M12
M6
M6
M6
M6
M12
15
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
APPX
SPECIFICATIONS
CHASSIS
Model
Front Suspension:
Front Fork Travel
Front Spring Free Length
<Limit>
Spring rate/Stroke
Optional Spring
Oil Capacity
Oil Level
Oil Grade
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
TIGHTENING TORQUE
Tightening Torque
Part to be Tightened
Remarks
Nm mkg ftlb
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
M8
M8
M12
M8
M8
M10
M10
M10
M10
M8
M6
M8
M6
M16
1
1
1
4
4
1
1
4
2
4
2
2
2
2
30
25
43
25
30
26
26
43
43
23
13
20
9
25
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
22
18
31
18
22
19
19
31
31
17
10
14
6.5
18
M10
M10
1
1
23
40
2.3
4.0
17
29
16
SPECIFICATIONS
APPX
ELECTRICAL
RX-Z
Model
Ignition System:
Ignition Timing (B.T.D.C.)
Advancer Type
14 at 1,500 r/min
Digital
C.D.I.:
Magneto-Model/Manufacturer
Pickup Coil Resistance/Color
Source Coil Resistance/Color
C.D.I. Unit-Model/Manufacturer
F5PV/YAMAHA
310 10 % at 20C (68F) / W/L - W/R
860 10 % at 20C (68F) / G/W - B/R
5PV/YAMAHA
Ignition coil:
Model/Manufacturer
Minimum Spark Gap
Primary Winding Resistance
Secondary Winding Resistance
4BE/YAMAHA
6mm (0.24 in) at 1,300 r/min
0.23 20 % at 20C (68F)
7.9 k 20 % at 20C (68F)
Charging System:
Type
Charging Current
C.D.I. Magneto
Ich (A)
4
3
Ich
2
1
0
10
17
APPX
SPECIFICATIONS
Model
Rectifier Regulator:
Model/Manufacture
No Load Regulated Voltage
Capacity
RX-Z
(Charging)
(Lighting)
(Charging)
(Lighting)
SH671 - 12/SHINDENGEN
14.0~15.0 V
Less than 13.3 V
8A
12 A
Battery:
Capacity
Specific Gravity
12 V, 3 AH
1.260
Horn:
Type/Quantity
Model/Manufacturer
Maximum Amperage
Plain type/1
5PV/NIKKO
5A
3FY/STANLEY
Circuit Breaker:
Type
Amperage for Individual/Quantity
Main
Reserve
Fuse
7Ax1
7Ax1
18
B/R
Or
W/R
B/W W/L
G/W
B/W
B Br
R
Br B
R
LOCK
OFF
ON
B/W
W/L W/R
W Sb
Y/R B
Sb W
B Y/R
W/R W/L
G/W B/R
B/R G/W
B/W
B/W
Or
Br R B
R
W B
R Y/R
B/W
Y/R
Y/R
A
B
Sb
P
Br
P
Br
MAIN HARNESS
RUN
OFF
5
6
W/L
W/R
G/W
B/R
W/L
W/R
G/W
B/R
SUB HARNESS
Br
Br
A
Br
Br
Br
Dg
Ch
G
B
L
Sb
B/R
Br
Dg
Ch
P Br/W
Br
Sb
B/R
Br
G
B
L
j
k
h
B/R
HI
LO
Dg
Sb
Y/R
Ch
P
A
P
OFF
ON
OFF
PUSH
L
N
R
B
G
B
G
B
Y/R L
B
P
Dg
Ch
Br/W
L Y/R
P B
Dg
Ch
Br/W
Y G
Dg
Ch
G/Y
Dg
Dg
Dg
Ch
Ch
G/Y G/Y
L
Ch
B
Y
G
B Ch
Dg
Y G
Sb
Y
G
B
B
Sb
B/R
G/Y
B
Sb
B/R
Br
Sb
Br
Br/W
Y
G
Br
Y
G
B
Ch B
Dg
G Y
Ch
cx
z
B
B
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
L
G/Y
Dg
L
G/Y
Dg
Ch
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
i
o
p
a
s
d
f
g
h
j
k
l
;
z
x
c
v
b
n
m
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