| L: | Apply a non-permanent locking agent to the threads. |
| LG: | Apply liquid gasket to the threads. |
| Lh: | Left-hand threads M : Apply molybdenum disulfide grease. |
| O: | Apply an oil to the threads and seating surface. |
| S: | Tighten the fasteners following the specified sequence. |
| SS: | Apply silicone sealant. |
| St: | Stake the fasteners to prevent loosening. |
| Threads diameter (mm) | Torque | ||
|---|---|---|---|
| N-m | kg-m | ft-lb | |
|
5 6 8 10 12 14 16 18 20 |
3.4 ~ 4.9 5.9 ~ 7.8 14 ~ 19 25 ~ 34 44 ~ 61 73 ~ 98 115 ~ 155 165 ~ 225 225 ~ 325 |
0.35 ~ 0.50 0.60 ~ 0.80 1.4 ~ 1.9 2.6 ~ 3.5 4.5 ~ 6.2 7.4 ~ 10.0 11.5 ~ 16.0 17.0 ~ 23.0 23 ~ 33 |
30 ~ 43 in-lb 52 ~ 69 in-lb 10.0 ~ 13.5 19.0 ~ 25 33 ~ 45 54 ~ 72 83 ~ 115 125 ~ 165 165 ~ 240 |
| Fastener | Torque | Remarks | ||
|---|---|---|---|---|
| N-m | kg-m | ft-lb | ||
| Fuel System: Carburetor Holder Bolts Fuel Tap Plate Screws Fuel Tap Knob Mounting Screw Fuel Pump Bolts |
12 7.8 1.0 3.9 |
1.2 0.80 0.10 0.40 |
104 in-lb 69 in-lb 9 in-lb 35 in-lb |
|
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Cooling System: Radiator Hose Clamp Bolts Coolant Air Bleeder Bolt (thermostat housing) Coolant Air Bleeder Boll (water pump) Coolant Drain Plugs Thermostatic Fan Switch Water Temperature Sensor |
2.0 7.8 9.8 9.8 18 7.8 |
0.20 0.80 1.0 1.0 1.8 0.80 |
17 in-lb 69 in-lb 87 in-lb 87 in-lb 13.0 69 in-lb |
SS |
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Engine Top End: Spark Plug Cylinder Head Cover Bolts Cylinder Head Bolts New Parts Cylinder Head Bolts Used Parts Pickup Coil Cover Bolts Cylinder Head Jacket Plugs (PT 1/2, PT 3/8) Camshaft Bearing Cap Bolts Camshaft Chain Tensioner Mounting Bolts Camshaft Sprocket Bolts Camshaft Chain Guide Bolts (Rear) Oil Hose Banjo Bolts |
14 9.8 47 43 12 20 12 12 15 12 25 |
1.4 1.0 4.8 4.4 1.2 2.0 1.2 1.2 1.5 1.2 2.5 |
10.0 87 in-lb 35 32 104 in-lb 14.5 104 in-lb 104 in-lb 11.0 104 in-lb 18.0 |
S, O (washer) S, O (washer) S L |
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Clutch: Clutch Cover Bolts Clutch Lever Holder Bolts Clutch Spring Bolts Clutch Hub Nut Clutch Cover Damper Bolts |
12 7.8 8.8 130 5.9 |
1.2 0.80 0.90 13.5 0.60 |
104 in-lb 69 in-lb 78 in-lb 98 52 in-lb |
L |
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Engine Lubrication System: Engine Drain Plug Crankcase Main Oil Passage Plug Oil Pan Bolts Oil Filter Oil Filter Mounting Bolt Oil Pressure Relief Valve Oil Pressure Switch Terminal Bolt Oil Pressure Switch Oil Hose Banjo Bolts Oil Hose Clamp Bolts (Lower Crankcase) Oil Hose Flange Bolts Oil Separator Cover Bolts (Upper Crankcase) |
20 15 12 9.8 29 15 1.5 15 25 8.8 12 9.8 |
2.0 1.5 1.2 1.0 3.0 1.5 0.15 1.5 2.5 0.90 1.2 1.0 |
14.5 11.0 104 in-lb 87 in-lb 22 11.0 13 in-lb 11.0 18.0 78 in-lb 104 in-lb 87 in-lb |
or hand-tight L SS L |
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Engine Removal/Installation: Engine Mounting Bolts Engine Mounting Adjuster Engine Mounting Bracket Bolts |
49 9.8 23 |
5.0 1.0 2.3 |
36 87 in-lb 16.5 |
|
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Crankshaft/Transmission: Oil Separator Cover Bolts Gear Positioning Lever Mounting Bolt Oil Pressure Switch Neutral Switch Shift Shaft Return Spring Pin Shift Drum Cam Bolts Shift Rod Plug (Left, M14) Connecting Rod Big End Cap Bolts (New) (In Assy) Crankcase Bolts Ø 8 Crankcase Bolts Ø 6 Timing Rotor Allen Bolt Crankcase Main Oil Passage Plug (Left, PT3/8) (Right M18) Oil Hose Banjo Bolts Oil Hose Bracket Bolts |
9.8 8.8 15 15 20 12 15 24 + 120° 22 + 120° 27 12 25 20 15 25 8.8 |
1.0 0.90 1.5 1.5 2.0 1.2 1.5 2.4 + 120° 2.2 + 120° 2.8 1.2 2.5 2.0 1.5 2.5 0.90 |
87 in-lb 78 in-lb 11.0 11.0 14.5 104 in-lb 11.0 17.5 + 120° 16.0 + 120° 20 104 in-lb 18.0 14.5 11.0 18.0 78 in-lb |
L SS L L R,O S S L |
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Wheels/Tires: Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut |
20 110 110 |
2.0 11.0 11.0 |
14.5 80 80 |
|
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Final Drive: Engine Sprocket Nut Torque Link Nuts Rear Sprocket Nuts Rear Sprocket Nuts (04-05) Rear Sprocket Studs |
125 34 75 59 - |
13.0 3.5 7.5 6.0 - |
94 25 54 43 - |
L |
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Brakes: Bleed Valves Brake Hose Banjo Bolts Master Cylinder Reservoir Cap Torque Link Nut Caliper Mounting Bolts (Front) Caliper Mounting Bolts (Rear) Caliper Bolts (Front) Front Caliper Pad Spring Screws Disc Mounting Bolts (Front) Disc Mounting Bolts (Rear) Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Front Brake Switch Mounting Screws Front Brake Reservoir Cap Screws Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Pushrod Locknut Brake Pedal Shaft Bolts (Right Footpeg Bolt) Rear Master Cylinder Bracket Locknut Brake Pedal Mounting Bolt |
7.8 25 1.5 34 34 25 21 2.9 23 23 1.0 5.9 1.0 1.5 9.8 23 18 8.8 18 8.8 |
0.80 2.5 0.15 3.5 3.5 2.5 2.1 0.30 2.3 2.3 0.10 0.60 0.10 0.15 1.0 2.3 1.8 0.90 1.8 0.90 |
69 in-lb 18.0 13 in-lb 25 25 18.0 15.0 26 in-lb 16.5 16.5 9 in-lb 52 in-lb 9 in-lb 13 in-lb 87 in-lb 16.5 13 78 in-lb 13.0 78 in-lb |
|
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Suspension: Front Fork Clamp Bolts (Upper, Lower) Front Fork Bottom Allen Bolts Front Axle Clamp Bolts Rear Shock Absorber Mounting Nuts Rear Shock Absorber Preload Adjuster Nut Tie-Rod Nuts Rocker Arm Pivot Shaft Nut Swing Arm Pivot Shaft Nut Swing Arm Pivot Shaft Nut (03-04) |
20 20 20 59 88 59 59 88 108 |
2.0 2.0 2.0 6.0 9.0 6.0 6.0 9.0 11.0 |
14.5 14.5 14.5 43 65 43 43 65 80 |
L |
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Steering: Steering Stem Head Nut Steering Stem Nut Handlebar Holder Mounting Bolts |
49 Hand-Tight or 4.9 23 |
5.0 Hand-Tight or 0.50 2.3 |
36 Hand-Tight or 43 in-lb 16.5 |
|
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Frame: Side Stand Bolt Side Stand Bracket Bolts Mounting Bolt Front Footpeg Stay Bolts Rear Footpeg Stay Bolts Tail Grip Bracket Mounting Bolts Center Stand Bolt |
44 49 25 25 25 44 |
4.5 5.0 2.5 2.5 2.5 4.5 |
32 36 18.0 18.0 18.0 32 |
L |
| Fastener | Torque | Remarks | ||
| N-m | kg-m | ft-lb | ||
| Electrical System: Fuel Gauge Bolt Pickup Coil Cover Bolts Timing Rotor Allen Bolts Alternator Cover Bolts Alternator Rotor Bolt Alternator Starter Bolts Starter Relay Terminal Nut Starter Motor Terminal Nut Starter Clutch Bolt Spark Plug Handlebar Switch Housing Clamp Screws Thermostatic Fan Switch Water Temperature Sensor Oil Pressure Switch Neutral Switch Speedometer & Trip Meter Mounting Screws Tail Light Mounting Nut Side Stand Switch |
3.9 12 25 12 78 12 4.9 4.9 34 14 3.4 18 7.8 15 15 - 5.9 3.9 |
0.4 1.2 2.5 1.2 8.0 1.2 0.50 0.50 3.5 1.4 0.35 1.8 0.80 1.5 1.5 - 0.6 0.4 |
35 in-lb 8.5 18.0 8.5 58 104 in-lb 43 in-lb 43 in-lb 25 10 30 in-lb 13.0 69 in-lb 11.0 11.0 - 52 in-lb 35 in-lb |
L SS SS L |
| Fuild | Capacity | |
|---|---|---|
| Metric | Standard | |
|
Unlead Gasoline Engine Oil** when filter is not removed Engine Oil** when filter is removed Engine Oil** when engine is completely dry Fork oil capacity when completely dry Fork oil capacity when changing oil Antifreeze (Green 50/50 mix) |
18.0 Liters 2.8 Liters 3.2 Liters 3.7 Liters 452 ml (+/- 4mL) 384 ml 2.5 Liters |
4.75 Gallons 0.74 Gallons 0.85 Gallons 0.98 Gallons 15.3 oz (+/- 0.13oz) 13 oz 2.65 quarts |
Copyright
2014