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RX - Z 2002 SUPPLEMENTARY SERVICE MANUAL 55K-F8197-E1

RX - Z

2002

SUPPLEMENTARY SERVICE MANUAL

55K-F8197-E1

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the RX- Z (2002). For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.

RX-Z (’85) SERVICE MANUAL: 55K-28197-W0

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 mechanic’s education into one manual, so per- sons 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.

HOW TO USE THIS MANUAL

PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.

NOTE:

cC

ffWARNING :

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.

PARTICULARLY IMPORTANT INFORMATION

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion 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 cor- rect disassembly and assembly procedures.

1 2 GEN INSP INFO ADJ 3 4 ENG COOL 5 6 CARB CHAS 7
1
2
GEN
INSP
INFO
ADJ
3
4
ENG
COOL
5
6
CARB
CHAS
7
8
ELEC
APPX
9
0
q
w
e
r
t
yu
i
op
B
LS
M
a
LT

ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number and content.

1 General information

2 Periodic inspection and adjustment

3 Engine

4 Cooling system

5 Carburetion

6 Chassis

7 Electrical

8 Appendices

Illustrated symbols 9 to r are used to identi- fy 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 di- agrams indicate the types of lubricants and lu- brication 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 ® )

CONTENTS

GENERAL INFORMATION

1

MOTORCYCLE IDENTIFICATION

1

FRAME SERIAL NUMBER

1

ENGINE SERIAL NUMBER

1

PERIODIC INSPECTIONS AND ADJUSTMENT

2

PERIODIC MAINTENANCE/LUBRICATION

2

CHASSIS

6

REAR WHEEL

6

FRONT FORK 7

8

INSTALLATION 9

HANDLEBARS

STEERING HEAD

11

REAR SHOCK ABSORBER AND SWINGARM

12

APPENDICES

13

SPECIFICATIONS

13

GENERAL SPECIFICATIONS 13

MAINTENANCE SPECIFICATIONS 14 ENGINE 14

15

CHASSIS 16

TIGHTENING TORQUE

TIGHTENING TORQUE

16

ELECTRICAL

17

MOTORCYCLE IDENTIFICATION

GEN

INFO

GEN INFO
GEN INFO
1
1

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

FRAME SERIAL NUMBER

The frame serial number 1 is stamped into the steering head pipe.

1
1

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into the elevated part of the right rear section of the en- gine.

NOTE:

The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.

Starting Serial Number:

5PV-000101

NOTE:

Designs and specifications are subject to change without notice.

Starting Serial Number: 5PV-000101 NOTE: Designs and specifications are subject to change without notice. –1–

–1–

INSP

ADJ

INSP ADJ
INSP ADJ

PERIODIC MAINTENANCE/LUBRICATION

PERIODIC INSPECTIONS AND ADJUSTMENT

PERIODIC MAINTENANCE/LUBRICATION

       

EVERY

6,000 km

12,000 km

No.

ITEM

 

CHECKS AND MAINTENANCE JOBS

Initial

or

or

(1,000 km)

6 months

12 months

     

(Whichever

(Whichever

comes first)

comes first)

1

 

* Fuel line

9 Check fuel hoses for cracks or damage.

 

9

Replace if necessary.

2

 

Spark plug

9

Check condition.

 

√√

9

Clean, regap or replace if necessary.

3

 

Air filter

9

Clean or replace if necessary.

 

     

9

Check electrolyte level and specific gravity.

     

4

* Battery

9

Correct or recharge if necessary.

9

Make sure that the breather hose is properly routed.

5

 

Clutch

9

Check operation.

 

√√

9

Adjust or replace cable.

     

9

Check operation, fluid level and vehicle for fluid

     

6

* Front brake

leakage. (See NOTE on page 6-5.)

√√

9

Correct accordingly.

9

Replace brake pads if necessary.

7

 

* Rear brake

9

Check operation.

 

√√

9

Adjust cable and replace brake shoes if necessary.

     

9

Check balance, runout, spoke tightness and for

 

8

* Wheels

damage.

9

Tighten spokes and rebalance, replace if necessary.

   
     

9

Check tread depth and for damage.

     

9

* Tires

9

Replace if necessary.

√ √

9

Check air pressure.

9

Correct if necessary.

10

 

* Wheel bearings

9

Check bearing for looseness or damage.

 

√ √

 

9

Replace if necessary.

     

9

Check swingarm pivoting point for play.

     

11

* Swingarm

9

Correct if necessary.

√ √

9

Lubricate with lithium soap based grease.

     

9

Check chain slack.

 

12

Drive chain

9

Adjust if necessary. Make sure that the rear wheel is properly aligned.

Every 500 km and after washing the motorcycle or riding in the rain

9

Clean and lubricate.

     

9

Check bearing play and steering for roughness.

     

13

* Steering bearings

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

     

14

* Chassis fasteners

tightened.

9

Tighten if necessary.

15

 

Sidestand/centerstand

9

Check operation.

 

9

Lubricate and repair if necessary.

16

 

* Front fork

9

Check operation and for oil leakage.

 

9

Correct accordingly.

17

 

* Rear shock absorber assemblies

9

Check operation and shock absorbers for oil leakage.

 

9

Replace shock absorber assembly if necessary.

18

 

* Carburetor

9

Check engine idling speed and starter operation.

 

√√

9

Adjust if necessary.

     

9

Check operation.

     

19

* Autolube pump

9

Correct if necessary.

√√

9

Bleed if necessary.

     

9

Check oil level and vehicle for oil leakage.

     

20

Transmission oil

9

Correct accordingly.

√√

9

Change oil at initial 1,000 km and thereafter every 24,000 km or 24 months (whichever comes first).

*: Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

2

PERIODIC MAINTENANCE/LUBRICATION

INSP

ADJ

INSP ADJ
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.

3

INSP

ADJ

INSP ADJ
INSP ADJ

PERIODIC MAINTENANCE/LUBRICATION

1

5 ~ 8 mm (0.2 ~ 0.3 in)

q

q

1 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

1

20 ~ 30 mm (0.8 ~ 1.2 in)

q

1 0.30 ~ 0.35 mm (0.012 ~ 0.014 in)

4

q

PERIODIC MAINTENANCE/LUBRICATION

1

2 ~ 3 mm (0.08 ~ 0.12 in)

q

INSP

ADJ

INSP ADJ
INSP ADJ

q

1 Front = 175 kPa (1.75 kg/cm 2 , 25 psi) Rear = 200 kPa (2.0 kg/cm 2 , 28 psi)

5

1

20 ~ 30 mm (0.8 ~ 1.2 in)

q

CHAS

CHAS

REAR WHEEL

REAR WHEEL

CHASSIS

1 Chain puller

0 Oil seal

o

Drive chain

2 Stopper

q

Bearing

p

Bearing

3 Cam lever

w

Spacer flange

a

Oil seal

4 Wear indicator

e

Bearing spacer

s

Collar

5 Spacer collar

r

Bearing

6 Tension bar

t

Damper

7 Brake lining plate

y

Sprocket shaft

8 Brake cam shaft

u

Sprocket hub

9 Brake lining

i

Driven sprocket

4 B TIRE SIZE: 10 Nm (1.0 kg•m,7.2 ft•lb) 3 90/90 - 18 51P C
4
B TIRE SIZE:
10 Nm (1.0 kg•m,7.2 ft•lb)
3
90/90 - 18 51P
C RIM SIZE: 1.40 X 18
2
LINING WEAR LIMIT:
1
D 2.0 mm (0.08 in)
LS
A USE NEW ONE
20 Nm (2.0 kg•m,14 ft•lb)
5
8
7
6
LS
A USE NEW ONE
9
0
20 Nm (2.0 kg•m,14 ft•lb)
B6202
q
w e
r
B6202Z
LS
t
y
u
i
o B6202Z
p
a
s
E RIM RUNOUT LIMIT:
F VERTICAL: 2.0 mm (0.078 in)
G LATERAL: 2.0 mm (0.078 in)
LS
26 Nm (2.6 kg•m,19 ft•lb)
85 Nm (8.5 kg•m,61 ft•lb)
DRIVE CHAIN FREE PLAY:
H
20 ~ 30 mm (0.8 ~ 1.2 in)

6

FRONT FORK

FRONT FORK

CHAS

CHAS

1 Rubber cap

8

Damper rod

t

Slide metal

2 Cap bolt

9

Inner tube

y

Outer tube

3 O-ring

0

Oil lock piece

u

Damper rod bolt

4 Spacer

q

Dust seal

5 Washer

w

Retaining clip

6 Fork spring

e

Oil seal

7 Rebound spring

r

Plate washer

23 Nm (2.3 kg•m,17 ft•lb) 1 2 3 4 5 6 7 30 Nm (3.0
23 Nm (2.3 kg•m,17 ft•lb)
1
2
3
4
5
6
7
30 Nm (3.0 kg•m,22 ft•lb)
8
q
w
e
r
t
9
y
0
A FORK OIL CAPACITY (EACH FORK):
165 cm 3 (5.82 Imp oz, 5.78 US oz)
RECOMENDED OIL:
u
B SAE 10W30 TYPE SE MOTOR OIL
23 Nm (2.3 kg•m,17 ft•lb)
FORK SPRING MINIMUM LENGTH:
C 428.1 mm (16.9 in)

7

CHAS

CHAS

HANDLEBARS

HANDLEBARS

1 Handlebar grip end

5 Handlebar (right)

8

Locknut

2 Grip rubber

6 Throttle and oil pump cable

9

Clutch cable

3 Leaf ring

assembly

0

Handlebar (left)

4 Throttle guide tube

7 Adjuster

q Collar

25 Nm (2.5 kg•m,18 ft•lb) 1 2 3 9 Nm (0.9 kg•m,6.5 ft•lb) 4 LS
25 Nm (2.5 kg•m,18 ft•lb)
1
2
3
9 Nm (0.9 kg•m,6.5 ft•lb)
4
LS
5
0
q
2
6
7
8
LS
20 Nm (2.0 kg•m,14 ft•lb)
9

8

HANDLEBARS

CHAS

CHAS
HANDLEBARS CHAS 4 2 3 1 1 INSTALLATION 1. Install: 9 Handlebars 2. Install: 9 Lever
4 2 3 1
4 2
3
1
1
1
HANDLEBARS CHAS 4 2 3 1 1 INSTALLATION 1. Install: 9 Handlebars 2. Install: 9 Lever

INSTALLATION

1.

Install:

9

Handlebars

2.

Install:

9

Lever holder 1 (left)

9

Handlebar grip 2 (left)

9

Handlebar switch 3 (left)

9

Handlebar grip end 4 (left)

 

Left handlebar install steps:

8Install the lever holder 1 to the handlebar.

  Bolt (lever holder):
 

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 handle- bar end.

NOTE:

 

Wipe off the excess adhesive with the clean rag.

::WARNING :

 

Leave the handlebar intact until the ad- hesive becomes dry enough to make the grip and handlebar stuck securely.

8Install the handlebar grip end (left).

  Handlebar grip end:
 

Handlebar grip end:

25 Nm (2.5 mkg, 18 ftlb)

 

8Install the handlebar switch (left).

9

CHAS

CHAS

HANDLEBARS

3. Install:

9

Handlebar grip (right)

9

Throttle cable

9

Handlebar switch (right)

NOTE:

Before installing the handlebar grip (right), apply a light coat of lithium - soap base grease onto the handlebar end.

1
1

2

::WARNING:

Provide the clearance of 1 mm (0.04 in) be- tween the handlebar grip 11 and the han- dlebar grip end 22. Otherwise, the grip may not move.

4.

Tighten:

9

Handlebar grip end (right)

Handlebar grip end: 25 Nm (2.5 m • kg, 18 ft • lb)
Handlebar grip end:

Handlebar grip end:

25

Nm (2.5 mkg, 18 ftlb)

9 Front brake master cylinder

Bolt (master cylinder bracket): 23 Nm (2.3 m • kg, 17 ft • lb)
Bolt (master cylinder bracket):

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

STEERING HEAD

STEERING HEAD

1

2

3

4

5 Ball race (lower - top)

6 Balls

7 Ball race (upper - bottom)

Stem nut Handle crown Ring nut Ball race cover

8

9

0

q Under bracket

Ball race (lower - top) Balls Ball race (lower - bottom)

CHAS

CHAS

40 Nm (4.0 kgm,29 ftlb)

2 1 3 4 LS 5 6 7 8
2
1
3
4
LS
5
6
7
8

9

25 Nm (2.5 kgm,18 ftlb)

38 Nm (3.8 kgm,27 ftlb)

LS q 0
LS
q
0

11

CHAS

CHAS

REAR SHOCK ABSORBER AND SWINGARM

REAR SHOCK ABSORBER AND SWINGARM

1 Chain adjuster

6

Thrust cover

2 Chain adjuster

7

Bearing

3 Chain guard

8

Collar

4 Shock absorber

9

Oil seal

5 Swingarm

0

Nipple

A SWING ARM FREE PLAY LIMIT: B END: 1.0 mm (0.04 in) C SIDE: 1.0
A SWING ARM FREE PLAY LIMIT:
B END: 1.0 mm (0.04 in)
C SIDE: 1.0 mm (0.04 in)
3
40 Nm (4.0 kg•m,29 ft•lb)
2
1
4
5
LS
LS
0
6
7
8
40 Nm (4.0 kg•m,29 ft•lb)
9
6
7
0
8
LS
LS
43 Nm (4.3 kg•m,31 ft•lb)
7
6

12

SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

APPENDICES

APPX

APPX
APPX

Model

 

RX-Z

Model Code Number:

5PV

Frame and Engine Starting Serial Number:

5PV-000101

 

Dimensions:

 

Overall Length Overall Width Overall Height Seat Height Wheelbase Minimum Ground Clearance

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)

Basic weight:

 

With Oil and Full Fuel Tank

118

kg (261 lb)

Spark plug:

 

Type/Manufacturer

BR9ES/NGK

 

Gap

0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

Transmission:

 

Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type Operation Gear Ratio

Herical gear 71/22 (3.227) Chain drive 46/16 (2.875) Constant mesh, 6-Speed Left foot operation

1st

34/12 (2.833)

 

2nd

29/16 (1.813)

3nd

26/19 (1.368)

4th

24/21 (1.143)

5th

23/23 (1.000)

6th

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

12V 35W/30W x 1 12V 5W/21W x 1 12V 10W x 4 12V 1.7W x 3

Tail/Brake Light

Flasher Light

Meter Light

–13–

APPX

APPX
APPX

SPECIFICATIONS

Model

 

RX-Z

Indicator Light Wattage/Quantity:

   

NEUTRAL

14V 3W x 1 14V 3W x 1 14V 3W x 1 14V 3W x 1

HIGH BEAM

OIL

TURN

MAINTENANCE SPECIFICATIONS

 

ENGINE

Model

 

RX-Z

Piston:

 

Piston size D/Measuring Point H

 

55.964 ~ 55.986 mm (2.203 ~ 2.204 in)/ 10 mm (0.41 in)

Piston Clearance

Piston Clearance 0.034 ~ 0.036 mm (0.00134 ~ 0.00142 in)
Piston Clearance 0.034 ~ 0.036 mm (0.00134 ~ 0.00142 in)
Piston Clearance 0.034 ~ 0.036 mm (0.00134 ~ 0.00142 in)

0.034 ~ 0.036 mm (0.00134 ~ 0.00142 in)

Piston Offset

0.5 mm (0.02 in) INside

Carburtor:

 

Type/Manufacturer/Quantity I.D. Mark Main Jet Main Air Jet Jet Needle-clip position Needle Jet Pilot Jet Pilot Air Screw Float Height Fuel Level

 

VM26SS/MIKUNI/1

5PV1 00

(M.J.)

# 195

(M.A.J.)

ø 0.5

(J.N.)

5FHE5-2

(N.J.)

O-8M

(P.J.)

# 22.5 1 and 1/4

(P.A.S.)

(F.H.)

21.0

± 1.0mm (0.2 in)

(F.L.)

0.5

mm (0.02 in)

Engine Idling Speed

(above the carburetor body edge) 1,250 ~ 1,350 r/min

Reed Valve:

Reed Valve:  
 

Thickness* Valve Stopper Height Valve Bending Limit

0.42

mm (0.017 in)

10.0

~ 10.6 mm (0.39 ~ 0.42 in)

 
  0.8 mm (0.031 in)

0.8

mm (0.031 in)

14

SPECIFICATIONS

APPX

APPX
APPX

Model

 

RX-Z

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 cm 3

 

(0.027 ~ 0.032 Imp oz, 0.062 ~ 0.030 US oz)

Maximum Output/200 Stroke

4.65

~ 5.15 cm 3

Adjusting mark (at idle)

(0.163 ~ 0.180 Imp oz, 0.158 ~ 0.175 US oz) Square Mark

TIGHTENING TORQUE

Tightening Torque Thread Part to be Tightened Part Name Q'ty Remarks Size Nm m•kg ft•lb
Tightening Torque
Thread
Part to be Tightened
Part Name
Q'ty
Remarks
Size
Nm
m•kg
ft•lb
Spark Plug
Reed Valve
Exhaust Pipe
Drain Plug
Push Rod #1
Bearing Cover Plate
Tachometer Housing
Stopper Lever
C.D.I. Magneto
M14
1
25
2.5
18
Bolt
M6
4
10
1.0
7.2
Stud bolt
M8
2
7
0.7
5.1
Bolt
M12
2
20
2.0
14
Nut
M6
1
7
0.7
5.1
Screw
M6
2
7
0.7
5.1
Bolt
M6
1
5
0.5
3.6
Bolt
M6
1
10
1.0
7.2
Nut
M12
1
83
8.3
60

15

APPX

APPX
APPX

CHASSIS

SPECIFICATIONS

Model

 

RX-Z

Front Suspension:

 

Front Fork Travel Front Spring Free Length <Limit> Spring rate/Stroke

Optional Spring

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

Oil Capacity

165

cm 3 (5.82 Imp oz, 5.78 US oz)

Oil Level

165

mm (6.5 in)

(From top of inner tube fully compressed without spring)

Oil Grade

Fork oil 10W or equivalent

TIGHTENING TORQUE Tightening Torque Part to be Tightened Thread Size Q'ty Remarks Nm m•kg ft•lb
TIGHTENING TORQUE
Tightening Torque
Part to be Tightened
Thread Size
Q'ty
Remarks
Nm
m•kg
ft•lb
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:
M8
1
30
3.0
22
M8
1
25
2.5
18
M12
1
43
4.3
31
M8
4
25
2.5
18
M8
4
30
3.0
22
M10
1
26
2.6
19
M10
1
26
2.6
19
M10
4
43
4.3
31
M10
2
43
4.3
31
M8
4
23
2.3
17
M6
2
13
1.3
10
M8
2
20
2.0
14
M6
2
9
0.9
6.5
M16
2
25
2.5
18
Bolt
M10
1
23
2.3
17
Nut
M10
1
40
4.0
29

16

SPECIFICATIONS

ELECTRICAL

APPX

APPX
APPX
Model RX-Z Ignition System: Ignition Timing (B.T.D.C.) Advancer Type 14° at 1,500 r/min Digital C.D.I.:
Model
RX-Z
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
Ω ± 10 % at 20°C (68°F) / W/L - W/R
860
Ω ± 10 % at 20°C (68°F) / 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 Ω ± 20 % at 20°C (68°F)
7.9
kΩ ± 20 % at 20°C (68°F)
Charging System:
Type
Charging Current
C.D.I. Magneto
Ich (A)
4
3
Ich
2
1
0
2
4
6
8
10
Engine Speed ( x 10 3 r/min)
Charging Coil Resistance (Color)
Lighting Coil Resistance (Color)
0.4
Ω ± 20 % at 20°C (68°F) / B-W
0.3
Ω ± 20 % at 20°C (68°F) / Y/R - B
Charging Current (A)

–17–

APPX

APPX
APPX

SPECIFICATIONS

Model

 

RX-Z

Rectifier Regulator:

 

Model/Manufacture No Load Regulated Voltage

(Charging)

SH671 - 12/SHINDENGEN 14.0~15.0 V Less than 13.3 V

(Lighting)

Capacity

(Charging)

8

A

(Lighting)

12

A

Battery:

 

Capacity

 

12

V, 3 AH

Specific Gravity

1.260

Horn:

 

Type/Quantity Model/Manufacturer Maximum Amperage

 

Plain type/1

5PV/NIKKO

5

A

Oil Level Switch:

 

Model/Manufacturer

3FY/STANLEY

Circuit Breaker:

 

Type Amperage for Individual/Quantity Main Reserve

   

Fuse

7

A x 1

7

A x 1

18

RX-Z (2002) WIRING DIAGRAM

1 B/R Or B W/R G/W B/W W/L B/W Br B B Br Sb W
1
B/R
Or
B
W/R
G/W
B/W
W/L
B/W
Br
B
B
Br
Sb
W
W
Sb
W/L
W/R
W/R W/L
LOCK
R
R
B
Y/R
Y/R
B
B/R
G/W
G/W
B/R
OFF
ON
B/W
B/W
q
B/W
Or
Br
R
B
W/L
W/L
B
w
W/R
W/R
0
B
R
R
W
W
G/W
G/W
7
Y/R
Y/R
8
B/R
B/R
B
W
B
R
Y/R
2
B/W
B
5
A
6
B
R
Sb
9
RUN
OFF
P
P
3
Br
Br
B
MAIN
HARNESS
SUB
HARNESS
4
B
Br
Br
s
A
Br
L
y
Br
t
Br
Dg
Dg
P
Br/W
Ch
Ch
Br
Br
Br
P
g
A
G
Sb
Sb
G
u
L
Y/R
Br/W
j
f
P
B
B/R
B/R
B
d
L
L
Br
Br
L
Br
B
i
o
p
a
k
h
Ch
HI
OFF
OFF
L
r
e
Dg
LO
ON
PUSH
N
R
G/Y
B
Sb
B/R
G
B
Y
l
Y
G
B
Ch
Dg
Dg
Dg
G
G/Y
G/Y
G
Dg
Dg
Y/R
L
L
Y/R
Ch
Ch
B
B
Y
G
B
P
P
B
Br/W
Br/W
Ch
Ch
L
B
G/Y
Y
;
Y
G
Dg
Ch
B
L
L
B
Y
G/Y
G/Y
B
Ch
Ch
B
G
Ch
Dg
Dg
Ch
Dg
Dg
Sb
Sb
Y
G
G
Y
Y
Y
c x
z
G
G
n
B
B
m
B
B
Sb
Sb
B
B/R
B/R
B
B
Dg
Ch
B
b
v

COLOR CODE

B

Black

P

Pink

Br/W

Brown/White

Br

Brown

R

Red

G/W

Green/White

Ch

Chocolate

Sb

Sky

blue

G/Y

Green/Yellow

Dg

Dark

green

W

White

W/L

White/Blue

G

Green

Y

Yellow

W/R

White/Red

L

Blue

B/R

Black/Red

Y/R

Yellow/Red

O

Orange

B/W

Black/White

 

1

Main switch

2

Fuse

3

Battery

4

Ground lead

5

Handlebar switch (right)

6

Engine stop switch

7

Rectifier/Regulator

8

C.D.I. Magneto

9

Neutral switch

0

C.D.I. Unit

q

Ignition coil

w

Spark plug

e

Rear brake switch

r

Front brake switch

t

Turn signal relay

y

Horn

u

Handlebar switch (left)

i

“LIGHTS” dimmer switch

o

“PASS” switch

p

“HORN” switch

a

“TURN” signal switch

s

Meter ass’y

d

“TURN” signal indicator light

f

“HI BEAM” indicator light

g

Meter light

h

“FUEL” meter

j

“OIL” warning indicator light

k

“NEUTRAL” indicator light

l

Fuel sender

;

Oil level gauge

z

Tail/Brake light

x

Rear turn signal light (right)

c

Rear turn signal light (left)

v

Front turn signal light (left)

b

Front turn signal light (right)

n

Sub lead wire

m

Headlight

YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN