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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

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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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

104

Model

(a) Model Year 2011

(b) Model Identification Name 1CK1

(c) Beginning Serial No. ME1CK192B2001003

(d) End Serial No.

105 Type Motorcycle Scooter Moped

106 ** Minimum weight

( Refer Manual ) 117 kgs

Right Side view of the vehicle Left Side view of the vehicle

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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2. Engine

201 Type of Engine Four Stroke Two Stroke

202 Number of Cylinders 1

203 **

a) Bore ** 57.00 mm

b) Stroke ** 58.70 mm

c) Conrod length ** 100 mm

d) Supercharging Yes No

e) Type and number of compressors

204 Cubic capacity (Refer Manual) 149.80 cc

205 **

(a) Minimum Volume of Cylinder Head

(Refer Manual) 9.90 cc

(b) No. of spark plugs per Cylinder 1

206 Compression Ratio (Refer Manual) 10.4 : 1

207 **

Piston

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

208

Material

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

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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Material Weight

208

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

211 a) Method of cooling Air Liquid Air & Liquid

b) Type of liquid Coolant with distilled water

212 Does the cylinder have a sleeve or liner

If yes, material Yes Material : , No

213 Cylinder barrel – coating Chrome Nickel Electrofusion

Others : DIASIL

214

Method of Induction

Reed Valve Rotary Valve

Piston Port Poppet Valve

215

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

Carburettor showing exit port

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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215

B) Fuel feed by Injection

a) Make Mikuni

b) Model AC28/1

c) Kind of fuel measurement Mechanical Electronic Hydraulic

d) Dimensions of intake pipe at the

throttle or slide location 31.5 mm

e) Number of effective fuel outlets Six

f) Position of injectors Inclined in Manifold

f1) Manifold / Cylinderhead Manifold Cylinderhead

g) Sensors of injection system Seven

h) Actuators of injection system Two

Injection System

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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Location of Sensors & Actuators

For Two Strokes Only

216

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

c) Width of Ports

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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Intake N/A mm

Transfer N/A mm

Boost N/A mm

Exhaust N/A mm

For Four Strokes only

217 **

Inlet valves

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 1

g) Type of valve springs Compression

If more than one spring Inner Outer

h) Maximum length of the spring under a load of

N

NA

i) External diameter of springs 19.65 +/- 0.2 mm

j) Diameter of spring wire 2.95

k) Number of spring coils 9

l) Maximum free length of springs 41.14 mm

218 **

Exhaust valves

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 1

g) Type of valve springs Compression

h) Maximum length of the spring under a load of

N

NA i) External diameter of springs 19.65 +/- 0.2 mm

j) Diameter of spring wire 2.95

k) Number of spring coils 9

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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l) Maximum free length of springs 41.14 mm

m) Diameter of pipe between manifold and

first silencer mm +/- 5%

219

Maximum valve lift

a) Intake 5.00 mm

b) Exhaust 5.00 mm

220 Type of valve operation Tappet Rockerarm Oscillating Lever

Direct Hydraulic

221

Ratio

a) Rocker Arm 1.380 /

b) Oscillating lever NA

c) Rocker Arm weight 86.00/92.00 gms

222 Overhead valve Yes No

223 Overhead CAM Yes No

224 Pushrod Yes No

225 Method of Cam shaft drive Chain

226

CAM Timing

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

227 **

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

c) Weight of the Cam with bearings** 226 gms

d) Number One

e) Location Head Cylinder

f) Number of bearings per shaft 2

g) Inside diameter of bearings 30.0 +/- 0.1 mm

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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Cam lift in mm (dismounted camshaft)

Intake Exhaust

Rotation

Angle in

Degrees

Lift in

Mm

Rotation

Angle in

Degrees

Lift in

mm

Rotation

angle in

Degrees

Lift in

Mm

Rotation

angle in

Degrees

Lift in

mm

0 5.2748 0

-5 +5 5.2439 -5 5.2819 +5 5.2515

-10 +10 -10 +10

-15 +15 -15 +15

-30 +30 -30 +30

-45 2.9543 +45 2.8875 -45 2.9211 +45 2.8727

-60 +60 -60 +60

-75 +75 -75 +75

-90 0.0244 +90 0.1634 -90 0.0417 +90 0.0833

-105 +105 -105 +105

-120 +120 -120 +120

-135 0.000 +135 0.000 -135 0.000 +135 0.000

-150 +150 -150 +150

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

Applicable to both 2 & 4 Stroke Engines

228 Type of Ignition T.C.I

229 Starting Devices Kick Self Both

230

a) Clutch wet dry

b) Method of operation Cable Hydraulic

c) Weight of Clutch Basket (Refer Manual) ** 2.240 kg

231 **

Transmission

Primary Drive

a) Method of primary drive Gear Belt Chain

b) If gear drive Helical 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

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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a) Diameter of pulleys mm

232 **

Gear Box

a) Shell Material Aluminium Alloy

b) No. of speeds Six

c) Material of gears Steel

Gear Ratio No. of teeth Thickness **

Drive 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

233 **

Secondary Drive

a) Method of Secondary Drive Chain Shaft Belt

b) Secondary Drive Ratio 3.133:1

c) If chain, No. of teeth ** Drive 15 Driven 47

d) If belt, diameter of pulleys

3 Chassis and Suspension

301 a) Main frame type Delta Box

b) Material (Gussets / Tubes) Steel Metal

Frame

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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302

Front Suspension

a) Method of suspension Telescopic Hydraulic fork

b) Front tube O.D. 33 mm

c) Lower Slider O.D. 42 mm

303

Rear Suspension

a) Method of suspension Mono Shock Twin Shock

b) Swinging Arm Type Tubular Rectangular Box Section

c) Material of Swinging Arm Steel

304

Wheels

a) Front wheel rim diameter (OD) 17 Inches

b) Width 2.16 Inches

305 a) Rear wheel rim diameter (OD) 17 Inches

b) Width 3.5 Inches

306 Oil Tank Capacity N/A liters

307

Fuel Tank

a) Capacity 12 Litres

b) Material Sheet Metal

308 Has the fuel system an electrical pump Yes

4 Exhaust System

401 Detachable baffles No

402 ** 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

FMSCI TDF No. :TDF-212MC002

Valid From :27th

May 2012

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501

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 No Yes No

c1) Internal diameter +/-1.5 mm +/-1.5 mm

c2) Number of linings per wheel

c3) Developed length of lining +/-1.5 mm +/-1.5 mm

c4) Width of lining +/- 1mm +/- 1mm

d) Disc Brakes Yes No 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

d6) External diameter of pads rubbing

surface 265 +/-1.5 mm 200 +/-1.5 mm

d7) Internal diameter of pads rubbing

surface 210 +/-1.5 mm 138 +/-1.5 mm

d8) Overall friction length of pads 61.5 +/-1.5 mm 59.2 +/-1.5 mm

d9) Ventilated discs Yes No Yes No

6 Radiator

601

Radiator Core Dimensions

a) Height 260 mm

b) Width 140 mm

c) Depth 40 mm

7 Airbox

701

a) Air Box Yes

b) Material PVC

c) RAM Air intake opening in fairing No

d) Dimension