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2012

FMSCI 2W Technical Data Form


No.TDF-212MC002

Yamaha YZF R15 v2.0

A25, Krishna Towers, 50 Sardar Patel Road, Chennai 600113


Ph : (91) (44) 22352673, 6450665, Fax : (91) (44) 22351684
email : fmsci @vsnl.com, web : www.fmsci.in

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

Article

Description

1. General
101

Manufacturer's Name

India Yamaha Motor Pvt. Ltd.

102

Manufacturer's address

A-3 Industrial Area, Noida-Dadri road, Gautam Budh


Nagar, Surajpur 201306

103

Brand name

YAMAHA

Model

104

(a) Model Year

2011

(b) Model Identification Name

1CK1

(c) Beginning Serial No.

ME1CK192B2001003

(d) End Serial No.


105
106 **

Type
Minimum weight
( Refer Manual )
Right Side view of the vehicle

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Motorcycle

Scooter

Moped

117 kgs

Left Side view of the vehicle

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

2. Engine
201

Type of Engine

202

Number of Cylinders

a) Bore **

57.00 mm

b) Stroke **

58.70 mm

c) Conrod length **

100 mm

203 **

Four Stroke

d) Supercharging

Yes

Two Stroke

No

e) Type and number of compressors


204
205 **
206

Cubic capacity (Refer Manual)

149.80 cc

(a) Minimum Volume of Cylinder Head


(Refer Manual)

9.90 cc

(b) No. of spark plugs per Cylinder

Compression Ratio (Refer Manual)

10.4 : 1

Piston

207 **

a) Material

Aluminium

b) Minimum Weight (Refer Manual) **

109.6 gms

c) No. of Rings per Piston

2 compression (one in each groove) + 2 oil rails


+ 1 expander in one groove.

d) Piston pin offset (Refer Manual) **

0.25 mm

e) Piston pin material

Steel

f) Piston pin weight

30 gms

Material

208

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a) Crankcase

Aluminium Alloy

b) Cylinder barrel

Aluminium Alloy

c) Cylinder head

Aluminium Alloy

d) Generator cover

Aluminium Alloy

e) Primary case cover

Aluminium Alloy

f) Clutch cover

Aluminium Alloy

g) Crankshaft cover

Aluminium Alloy

h) Gear Box cover

Aluminium Alloy

i) Ignition cover

Aluminium Alloy

k) Cylinder head cover (valve)

Aluminium Alloy

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

Material

Weight

l) Crank shaft ** (Refer Manual)

Steel

2665 gms **

m) Conrod ** (with cap, bolts and shell


bearings) (Refer Manual)

Steel

129.8 gms **

209

Thickness of tightened cylinder head gasket

0.3 mm +/- 0.1 mm

210

Position of Cylinder & head relative


to the Crank Case

Forward inclined single cylinder degree

208

a) Method of cooling

Air

Liquid

Air & Liquid

211
b) Type of liquid

Coolant with distilled water

212

Does the cylinder have a sleeve or liner


If yes, material

213

Cylinder barrel coating

Yes Material :
Chrome

Nickel

No
Electrofusion

Others : DIASIL
214

Reed Valve

Rotary Valve

Piston Port

Poppet Valve

Method of Induction

A) Fuel feed by Carburettor


a) Make

N/A

b) Type / Model

N/A

c) Venturi diameter

N/A mm +/- 0.25 mm

d)Maximum diameter of Carburettor exit port

N/A mm

e) Length of adaptor

N/A mm

215

Carburettor showing exit port

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

View of Engine / Crankcase Assembly Left Side / Right Side / Front Side

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

B) Fuel feed by Injection


a) Make

Mikuni

b) Model

AC28/1

c) Kind of fuel measurement


215

Mechanical

d) Dimensions of intake pipe at the


throttle or slide location

Hydraulic

31.5 mm

e) Number of effective fuel outlets

Six

f) Position of injectors

Inclined in Manifold

f1) Manifold / Cylinderhead

Electronic

Manifold

g) Sensors of injection system

Seven

h) Actuators of injection system

Two

Cylinderhead

Injection System

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

Location of Sensors & Actuators

For Two Strokes Only


a) Number of Ports

N/A

Total

N/A

Intake

N/A

Transfer

N/A

Boost

N/A

Exhaust

N/A

216

b) Height of Ports
Intake

N/A mm

Transfer

N/A mm

Boost

N/A mm

Exhaust

N/A mm

216

c) Width of Ports

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

Intake

N/A mm

Transfer

N/A mm

Boost

N/A mm

Exhaust

N/A mm

For Four Strokes only


Inlet valves

217 **

a) Number

Two

b) Diameter **

19.50 mm

c) Stem dia **

4.50 mm

d) Overall length **

85.20 mm

e) Weight **

16.0 gms

f) Number of springs per valve

g) Type of valve springs

Compression

If more than one spring

Inner

Outer
under a load of
N

h) Maximum length of the spring


i) External diameter of springs

19.65 +/- 0.2 mm

j) Diameter of spring wire

2.95

k) Number of spring coils

l) Maximum free length of springs

41.14 mm

NA

Exhaust valves

218 **

a) Number

Two

b) Diameter **

17.00 mm

c) Stem dia **

4.50 mm

d) Overall length **

85.0 mm

e) Weight **

14.00 gms

f) Number of springs per valve

g) Type of valve springs

Compression
under a load of
N

h) Maximum length of the spring

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i) External diameter of springs

19.65 +/- 0.2 mm

j) Diameter of spring wire

2.95

k) Number of spring coils

NA

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

l) Maximum free length of springs

41.14 mm

m) Diameter of pipe between manifold and


first silencer

mm +/- 5%

Maximum valve lift


219

220

a) Intake

5.00 mm

b) Exhaust

5.00 mm
Tappet Rockerarm

Oscillating Lever

Direct

Hydraulic

Type of valve operation


Ratio
a) Rocker Arm

1.380 /

b) Oscillating lever

NA

c) Rocker Arm weight

86.00/92.00 gms

221

222

Overhead valve

Yes

No

223

Overhead CAM

Yes

No

224

Pushrod

Yes

No

225

Method of Cam shaft drive

Chain

CAM Timing

226

a) Inlet opens

29.0 Degree BTDC

b) Inlet closes

59.0 Degree ABDC

c) Exhaust opens

59.0 Degree BBDC

d) Exhaust closes

29.0 Degree ATDC

CAM dimensions
a) Inlet **

A=25.2 +/-0.1 mm
B=30.2 +/-0.1 mm

b) Exhaust **

A=25.2 +/-0.1 mm
B=30.2 +/-0.1 mm

227 **

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c) Weight of the Cam with bearings**

226 gms

d) Number

One

e) Location

Head Cylinder

f) Number of bearings per shaft

g) Inside diameter of bearings

30.0 +/- 0.1 mm

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

Cam lift in mm (dismounted camshaft)


Intake
Rotation
Angle in
Degrees

Lift in
Mm

5.2748

Exhaust

Rotation
Angle in
Degrees

Lift in
mm

Rotation
angle in
Degrees

Lift in
Mm

Rotation
angle in
Degrees

Lift in
mm

5.2819

+5

5.2515

-5

+5

-10

+10

-10

+10

-15

+15

-15

+15

-30

+30

-30

+30

-45

2.9543

5.2439

+45

2.8875

-5

-45

2.9211

+45

-60

+60

-60

+60

-75

+75

-75

+75

-90

0.0244

+90

0.1634

-90

0.0417

2.8727

+90

0.0833

-105

+105

-105

+105

-120

+120

-120

+120

-135

0.000

-150

+135

0.000

+150

-135

0.000

-150

+135

0.000

+150

A shift of +/- 2 degrees of the whole measurement is accepted


Applicable to both 2 & 4 Stroke Engines
228

Type of Ignition

229

Starting Devices

Kick

a) Clutch

wet

dry

b) Method of operation

Cable

Hydraulic

230

c) Weight of Clutch Basket (Refer Manual) **

T.C.I
Self

Both

2.240 kg

Transmission
Primary Drive

231 **

a) Method of primary drive

Gear

b) If gear drive

Helical

Belt

Chain
Straight Cut

Primary Drive Ratio

3.042:1

If gears / Chain

Drive

Driven

a) No. of teeth **

73

24

b) Thickness **

12.00 mm

14.20 mm

if belt

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

a) Diameter of pulleys

mm

Gear Box
a) Shell Material

Aluminium Alloy

b) No. of speeds

Six

c) Material of gears

Steel

232 **

Gear

Ratio

No. of teeth
Drive

Thickness **

Driven

Drive

Driven

First

2.833

12

34

11.3mm

13.6 mm

Second

1.875

16

30

11.1 mm

11.0 mm

Third

1.364

22

30

10.6 mm

11.6 mm

Fourth

1.143

21

24

11.0 mm

11.0 mm

Fifth

0.957

23

22

12.7 mm

12.7 mm

Sixth

0.840

25

21

12.3 mm

12.7 mm

Secondary Drive
a) Method of Secondary Drive
233 **

Chain

Shaft

b) Secondary Drive Ratio

3.133:1

c) If chain, No. of teeth **

Drive 15 Driven 47

Belt

d) If belt, diameter of pulleys


Chassis and Suspension

3
a) Main frame type

Delta Box

b) Material (Gussets / Tubes)

Steel Metal

301

Frame

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

Front Suspension
a) Method of suspension

Telescopic Hydraulic fork

b) Front tube O.D.

33 mm

c) Lower Slider O.D.

42 mm

302

Rear Suspension
a) Method of suspension

Mono Shock

b) Swinging Arm Type

Tubular

Twin Shock

303
c) Material of Swinging Arm

Rectangular Box Section

Steel

Wheels
304

a) Front wheel rim diameter (OD)

17 Inches

b) Width

2.16 Inches

a) Rear wheel rim diameter (OD)

17 Inches

b) Width

3.5 Inches

Oil Tank Capacity

N/A liters

305
306

Fuel Tank
307

308

a) Capacity

12 Litres

b) Material

Sheet Metal

Has the fuel system an electrical pump

Yes

Exhaust System

4
401

Detachable baffles

No

Weight of the silencer system with bolts for


fixing the same **

5.60 kgs

403

Inner diameter of the bend of the silencer

26.0 mm

404

Anti Pollution System : Description

402 **

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FMSCI TDF No. :TDF-212MC002


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Valid From :27 May 2012

5. Brakes

Front

Rear

a) Number of pistons per caliper

Two

One

b) OD of piston in caliper

25.4 mm

31.8 mm

c) Drum Brakes

Yes

c1) Internal diameter

No

Yes

No

+/-1.5 mm

+/-1.5 mm

c3) Developed length of lining

+/-1.5 mm

+/-1.5 mm

c4) Width of lining

+/- 1mm

+/- 1mm

c2) Number of linings per wheel

d) Disc Brakes
501

Yes

Yes

No

d1) Number of pads per wheel

Two

Two

d2) Number of calipers per wheel

One

One

d3) Caliper Material

Aluminium

Aluminium

d4) Thickness of new disc

4.00+/-0.2+/- 1 mm

4.50+/-0.2+/- 1 mm

d5) External diameter of disc

267+/-0.3 +/-1.5
mm

220+/-0.3 +/-1.5
mm

265 +/-1.5 mm

200 +/-1.5 mm

210 +/-1.5 mm

138 +/-1.5 mm

61.5 +/-1.5 mm

59.2 +/-1.5 mm

d6) External diameter of pads rubbing


surface
d7) Internal diameter of pads rubbing
surface
d8) Overall friction length of pads
d9) Ventilated discs

No

Yes

No

Yes

No

Radiator
Radiator Core Dimensions
a) Height

260 mm

b) Width

140 mm

c) Depth

40 mm

601

Airbox
a) Air Box

Yes

b) Material

PVC

c) RAM Air intake opening in fairing

No

701

d) Dimension

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