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General Specifications Engine Specifications Chassis Specifications Electrical Specifications Engine Tightening Torques Chassis Tightening Torques

General Specifications

Item	Standard	Limit
Model Code	5LV5 (USA except for California)
	5LV6 (CDN)
	5LV7 (California)
Dimensions
Overall length	2,125 mm (83.7 in)
Overall width	765 mm (30.1 in)
Overall height	1,190 mm (46.9 in)
Seat height	820 mm (32.3 in)
Wheelbase	1,450 mm (57.1 in)
Minimum ground clearance	140 mm (5.5 in)
Minimum turning radius	2,900 mm (114.2 in)
Weight
Wet (with oil and a full fuel tank)	231 kg (509 lb)
	232 kg (512 lb) (for california)
Dry (without oil and fuel)	208 kg (459 lb)
	209 kg (461 lb) (for california)
Maximum load (total of cargo, rider, passenger, and accessories)	189 kg (417 lb)
	188 kg (415 lb) (for california)

Engine Specifications

Item	Standard	Limit
Engine
Engine type	Liquid-cooled, 4-stroke, DOHC
Displacement	998 cm 3
Cylinder arrangement	Forward-inclined parallel 4-cylinder
Bore & stroke	74 x 58 mm (2.91 x 2.28 in)
Compression ratio	11.4 : 1
Engine idling speed	1,050 - 1,150 r/min
Vacuum pressure at engine idling speed	30 kPa (225 mmHg, 8.86 in Hg)
Standard compression pressure (at sea level)	1,450 kPa (14.5 kg/cm2 , 206 psi) at 400 r/min
Fuel
Recommended fuel	Unleaded fuel (for USA)
	Regular unleaded gasoline (for CDN)
Fuel tank capacity:
Total (including reserve)	21 L (18.5 Imp qt, 22.2 US qt)
Reserve only	4.0 L (3.52 Imp qt, 4.22 US qt)
Engine Oil
Lubrication system	Wet sump
Recommended oil:	Yamalube 4 (20W40) or SAE 20W40 type SE motor oil
Quantity:
Total amount	3.7 L (3.2 Imp qt, 3.8 US qt)
Without oil filter cartridge replacement	2.8 L (2.4 Imp qt, 2.9 US qt)
With oil filter cartridge replacement	3.0 L (2.6 Imp qt, 3.1 US qt)
Oil pressure (hot)	45 kPa (0.45 kg/cm2 , 6.40 psi) at 1,100 r/min
Relief valve opening pressure	490 - 570 kPa (4.9 - 5.7 kg/cm2 , 69.7 - 81.1 psi)
Oil filter
Oil filter type	Cartridge (paper)
Part number	5GH-13440-00-00
Oil Pump
Oil pump type	Trochoidal
Inner-rotor-to-outer-rotor-tip clearance	0.09 - 0.15 mm (0.004 - 0.006 in)
Outer-rotor-to-oil-pump-housing clearance	0.03 - 0.08 mm (0.001 - 0.003 in)
Bypass valve opening pressure	180 - 220 kPa (1.8 - 2.2 kg/cm2 , 25.6 - 31.3 psi)
Relief valve operating pressure	490 - 570 kPa (71.1 - 82.7 psi)
Oil pressure (hot)	45 kPa @ 1100 rpm (6.5 psi @ 1100 rpm)
Cooling System
Radiator capacity	2.4 L (2.11 Imp qt, 2.53 US qt)
Radiator cap opening pressure	95 - 125 kPa (0.95 - 1.25 kg/cm2 , 13.1 - 17.8 psi)
Radiator core
Width	340 mm (13.4 in)
Height	238 mm (9.4 in)
Depth	24 mm (0.94 in)
Coolant reservoir capacity	0.3 L (0.26 Imp qt, 0.32 US qt)
Water pump:
Water pump type	Single-suction centrifugal pump
Reduction ratio	68/43 x 28/28 (1.581)
Max. impeller shaft tilt		0.15 mm (0.006 in)
Starting system type	Electric starter
Spark plugs
Model (manufacturer) x quantity	CR9E / U27ESR-N (NGK / DENSO) x 4
Spark plug gap	0.7 - 0.8 mm (0.028 - 0.031 in)
Cylinder head
Volume	13.45 - 14.05 cc (0.82 - 0.86 in3)
Max. warpage:		0.1 mm (0.004 in)
Camshafts
Drive system	Chain drive (right)
Camshaft cap inside diameter	24.500 - 24.521 mm (0.9646 - 0.9654 in)
Camshaft journal diameter	24.459 - 24.472 mm (0.9630 - 0.9635 in)
Camshaft-journal-to-camshaft-cap clearance	0.028 - 0.062 mm (0.0011 - 0.0024 in)
Intake camshaft lobe dimensions:
Measurement A	32.5 - 32.6 mm (1.2795 - 1.2835 in)	32.4 mm (1.2756 in)
Measurement B	24.95 - 25.05 mm (0.9823 - 0.9862 in)	24.85 mm (0.9783 in)
Measurement C	7.45 - 7.65 mm (0.2933 - 0.3012 in)
Exhaust camshaft lobe dimensions:
Measurement A	32.95 - 33.05 mm (1.2972 - 1.3012 in)	32.85 mm (1.2933 in)
Measurement B	24.95 - 25.05 mm (0.9823 - 0.9862 in)	24.85 mm (0.9783 in)
Measurement C	7.75 - 7.95 mm (0.3051 - 0.3126 in)
Max. camshaft runout:		0.03 mm (0.0012 in)
Valve Timing
Intake-open (BTDC)	32°
Intake-closed (ABDC)	56°
Exhaust-open (BBDC)	61°
Exhaust-closed (ATDC)	35°
Overlap angle	67°
Timing chain
Model / number of links	RH2015 / 130
Tensioning system	Automatic
Valves, valve seats, valve guides
Valve clearance (cold)	0.11 - 0.20 mm (0.0043 - 0.0079 in)
Intake	0.21 - 0 25 mm (0 0083 - 0 0098 in)
Exhaust Valve Dimensions: Head Diameter Face Width Seat Width Margin Thickness
Valve head diameter A:
Intake	22.9 - 23.1 mm (0.9016 - 0.9094 in)
Exhaust	24.4 - 24.6 mm (0.9606 - 0.9685 in)
Valve face width B:
Intake	1.76 - 2.90 mm (0.0693 - 0.1142 in)
Exhaust	1.76 - 2.90 mm (0.0693 - 0.1142 in)
Valve seat width C:
Intake	0.9 - 1.1 mm (0.035 - 0.043 in)
Exhaust	0.9 - 1.1 mm (0.035 - 0.043 in)
Valve margin thickness D:
Intake	0.5 - 0.9 mm (0.020 - 0.035 in)
Exhaust	0.5 - 0.9 mm (0.020 - 0.035 in)
Valve stem diameter:
Intake	3.975 - 3.900 mm (0.1565 - 0.1535 in)	3.945 mm (0.1553 in)
Exhaust	4.465 - 4.480 mm (0.1758 - 0.1764 in)	4.43 mm (0.1744 in)
Valve guide inside diameter:
Intake	4.000 - 4.012 mm (0.1575 - 0.1580 in)	4.05 mm (0.1594 in)
Exhaust	4.500 - 4.512 mm (0.1772 - 0.1776 in)	4.55 mm (0.1791 in)
Valve-stem-to-valve-guide clearance:
Intake	0.010 - 0.037 mm (0.0004 - 0.0015 in)	0.08 mm (0.0031 in)
Exhaust	0.020 - 0.047 mm (0.0008 - 0.0019 in)	0.10 mm (0.0039 in)
Valve stem runout:		0.01 mm (0.0004 in)
Valve seat width:
Intake	0.9 - 1.1 mm (0.035 - 0.043 in)
Exhaust	0.9 - 1.1 mm (0.035 - 0.043 in)
Valve seat material - intake	PB6
Valve seat material - exhaust	PB7W
Valve springs free length:
Intake	38.90 mm (1.53 in)
Exhaust	40.67 mm (1.60 in)
Spring rate - intake (K1)	20.3 N/mm (115.91 lb/in)
Spring rate - intake (K2)	26.75 N/mm (152.74 lb/in)
Spring rate - exhaust (K1)	20.74 N/mm (118.43 lb/in)
Spring rate - exhaust (K2)	27.83 N/mm (158.91 lb/in)
Installed length (valve closed):
Intake	34.50 mm (1.36 in)
Exhaust	35.00 mm (1.38 in)
Compressed spring force (installed):
Intake	82 - 96 N (8.2 - 9.6 kg, 18.4 - 25.4 lb)
Exhaust	110 - 126 N (11.0 - 12.6 kg, 24.7 - 28.3 lb)
Spring tilt:
Intake		2.5° / 1.7 mm (2.5° / 0.067 in)
Exhaust		2.5° / 1.8 mm (2.5° / 0.071 in)
Winding direction (top view):
Intake	Clockwise
Exhaust	Clockwise
Cylinders
Cylinder arrangement	Forward-inclined, parallel 4-cylinder
Bore & stroke	74 x 58 mm (2.91 x 2.28 in)
Compression ratio	11.4 : 1
Bore	74.00 - 74.01 mm (2.9134 - 2.9138 in)
Max. taper		0.05 mm (0.0016 in)
Max. out-of-round		0.05 mm (0.0016 in)
Pistons
Piston part number	4XV-11631-00
Piston-to-cylinder clearance	0.030 - 0.055 mm (0.001 - 0.002 in)	0.12 mm (0.005 in)
Diameter D:	73.955 - 73.970 mm (2.9118 - 2.9122 in)
Height H	5 mm (0.20 in)
Piston pin bore (in the piston):
Diameter	17.002 - 17.013 mm (0.6694 - 0.6698 in)	17.043 mm (0.6710 in)
Offset	0.5 mm (0.0197 in)
Offset direction	Intake side
Piston pins:
Outside diameter	16.991 - 17.000 mm (0.6689 - 0.6693 in)	16.971 mm (0.6681 in)
Piston-pin-to-piston-pin-bore clearance	0.002 - 0.022 mm (0.00008 - 0.00087 in)	0.072 mm (0.0028 in)
Piston rings:
top ring -
Ring type	Barrel
Dimensions (B x T)	0.90 x 2.75 mm (0.035 x 0.108 in)
End gap (installed)	0.32 - 0.44 mm (0.010 - 0.020 in)
Ring side clearance	0.030 - 0.065 mm (0.0012 - 0.0026 in)
Plating/coating	Chrome plated/ferox coating
2nd ring -
Ring type	Taper
Dimensions (B x T)	0.8 x 2.8 mm (0.031 x 0.110 in)
End gap (installed)	0.43 - 0.58 mm (0.017 - 0.023 in)
Ring side clearance	0.020 - 0.055 mm (0.0008 - 0.0022 in)
Plating/coating	Parkerrizing
Oil ring -
Dimensions (B x T)	1.5 x 2.6 mm (0.059 x 0.101 in)
End gap (installed)	0.10 - 0.35 mm (0.004 - 0.014 in)
Plating/coating	Chrome plated/parkerrizing
Connecting rods
Crankshaft-pin-to-big-end-bearing clearance	0.031 - 0.055 mm (0.0012 - 0.0022 in)
Bearing color code	–1 = Violet 0 = White 1 = Blue 2 = Black
Connecting rod length	110.45 - 110.55 mm (4.348 - 4.352 in)
Crankshaft
Width A	52.40 - 57.25 mm (2.063 - 2.254 in)
Width B	300.75 - 302.65 mm (11.84 - 11.92 in)
Max. runout C		0.03 mm (0.0012 in)
Big end side clearance D	0.160 - 0.262 mm (0.006 - 0.010 in)
Crankshaft-journal-to-crankshaft-journal-bearing clearance	0.029 - 0.053 mm (0.0011 - 0.0021 in)
Bearing color code	–1 = Pink/violet 0 = Pink/white 1 = Pink/blue 2 = Pink/black 3 = Pink/brown
Position of thrust bearing	#4 Journal
Clutch
Clutch type	Wet, multiple disc
Clutch release method	Cam (pull rod type)
Clutch release method operation	Cable operation
Operation	Left-hand operation
Clutch cable free play (at the end of the clutch lever)	10 - 15 mm (0.39 - 0.59 in)
Friction plates:
Thickness	2.92 - 3.08 mm (0.115 - 0.121 in)	2.82 mm (0.111 in)
Plate quantity	8
Thickness	3.42 - 3.58 mm (0.135 - 0.141 in)	3.32 mm (0.131 in)
Plate quantity	1
Clutch plates:
Thickness	1.9 - 2.1 mm (0.075 - 0.083 in)
Plate quantity	8
Max. warpage		0.1 mm (0.004 in)
Clutch springs:
Free length	50 mm (1.97 in)
Spring quantity	6
Transmission
Transmission type	Constant mesh, 6-speed
Primary reduction system	Spur gear
Primary reduction ratio	68/43 (1.581)
Secondary reduction system	Chain drive
Secondary reduction ratio	44/16 (2.750)
Operation	Left-foot operation
Gear ratios:
1st gear	35/14 (2.500)
2nd gear	35/19 (1.842)
3rd gear	30/20 (1.500)
4th gear	28/21 (1.333)
5th gear	30/25 (1.200)
6th gear	29/26 (1.115)
Max. main axle runout		0.08 mm (0.003 in)
Max. drive axle runout		0.08 mm (0.003 in)
Shifting mechanism
Shift mechanism type	Guide bar
Max. shift fork guide bar bending		0.1 mm (0.004 in)
Installed shift rod length	260 mm (10.2 in)
Air filter type	Dry element
Fuel pump
Pump type	Electrical
Model (manufacturer)	4SV (MITSUBISHI)
Output pressure	20 kPa (0.2 kg/cm2, 2.8 psi)
Carburetors
Model (manufacturer) x quantity	BSR37 (MIKUNI) x 4
Throttle cable free play (at the flange of the throttle grip)	3 - 5 mm (0.12 - 0.20 in)
ID mark	5LV5 40
Main jet	Carburetors 1 and 4: #132.5
	Carburetors 2 and 3: #130
Main air jet	#80
Jet needle	Carburetor 1 and 4: 5D129-3/5
	Carburetor 2 and 3: 5D130-3/5
Needle jet	P-OM
Pilot air jet	#85
Pilot outlet	1.0
Pilot jet	#15
Bypass 1	0.9
Bypass 2	0.9
Bypass 3	0.9
Pilot screw turns out	2.0
Valve seat size	1.5
Starter jet 1	#42.5
Starter jet 2	0.8
Throttle valve size	#115
Fuel level (above the line on the float chamber)	3.0 - 4.0 mm (0.118 - 0.157 in)
Idling Condition
Engine idle speed	1050 - 1150 rpm
CO% with AIS blocked	4 - 5%
Intake vacuum	225 mm Hg (8.858 in Hg)
Water temperature	95 - 105°C
oil temperature	85 - 95°C
Max. EXUP cable free play (at the EXUP valve pulley)	1.5 mm (0.059 in)

Chassis Specifications

Item	Standard	Limit
Frame
Frame type	Double cradle
Caster angle	26°
Trail	104 mm (4.09 in)
Front wheel
Wheel type	Cast wheel
Rim:
Size	17 x MT3.50
Material	Aluminum
Wheel travel	140 mm (5.51 in)
Wheel runout:
Max. radial wheel runout		1 mm (0.04 in)
Max. lateral wheel runout		0.5 mm (0.02 in)
Rear wheel
Wheel type	Cast wheel
Rim:
Size	17 x MT5.50
Material	Aluminum
Wheel travel	135 mm (5.31 in)
Wheel runout:
Max. radial wheel runout		1 mm (0.04 in)
Max. lateral wheel runout		0.5 mm (0.02 in)
Front tire
Tire type	Tubeless
Size	120/70 ZR17 (58W)
Model (manufacturer)	MEZ4Y FRONT (METZELER)
	BT020F U (BRIDGESTONE)
Tire pressure (cold):
0 - 90 kg	250 kPa (2.5 kgf/cm2, 36 psi)
90 - 201 kg	250 kPa (2.5 kgf/cm2, 36 psi)
High-speed riding	250 kPa (2.5 kgf/cm2, 36 psi)
Min. tire tread depth		1.0 mm (0.04 in)
Rear tire
Tire type	Tubeless
Size	180/55 ZR17 (73W)
Model (manufacturer)	MEZ4Y (METZELER)
	BT020R U (BRIDGESTONE)
Tire pressure (cold):
0 - 90 kg	270 kPa (2.7 kgf/cm2, 39 bar)
90 - 201 kg	290 kPa (2.9 kgf/cm2, 42 bar)
High-speed riding	290 kPa (2.9 kgf/cm2, 42 bar)
Min. tire tread depth	1.0 mm (0.04 in)
Front brakes
Brake type	Dual-disc brake
Operation	Right-hand-operation
Brake lever free play	2.3 - 11.5 mm (0.09 - 0.45 in)
Recommended fluid	DOT 4
Brake discs:
Diameter x thickness	298 x 5 mm (11.7 x 0.20 in)
Min. thickness		4.5 mm (0.18 in)
Max. deflection		0.1 mm (0.004 in)
Brake pad lining thickness:	5.5 mm (0.22 in)	0.5 mm (0.02 in)
Master cylinder inside diameter	14 mm (0.05 in)
Caliper cylinder inside diameter	30.2 mm (1.19 in) and 27 mm (1.06 in)
Rear brake
Brake type	Single-disc brake
Operation	Right-foot operation
Brake pedal position (from the top of the brake pedal to the top of the rider footrest)	35 - 40 mm (1.38 - 1.57 in)
Brake pedal free play	4.0 - 8.5 mm (0.16 - 0.33 in)
Recommended fluid	DOT 4
Brake discs:
Diameter x thickness	267 x 5 mm (10.51 x 0.20 in)
Min. thickness		4.5 mm (0.18 in)
Max. deflection		0.1 mm (0.004 in)
Brake pad lining thickness:	5.5 mm (0.22 in)	0.5 mm (0.02 in)
Master cylinder inside diameter	12.7 mm (0.5 in)
Caliper cylinder inside diameter	42.9 mm (1.69 in)
Front suspension
Suspension type	Telescopic fork
Front fork type	Coil spring/oil damper
Front fork travel	140 mm (5.51 in)
Spring:
Free length	344.0 mm (13.5 in)
Spacer length	66.0 mm (2.60 in)
Installed length	320.0 mm (12.6 in)
Spring rate (K1)	7.8 N/mm (0.78 kg/mm, 43.7 lb/in)
Spring rate (K2)	11.8 N/mm (1.2 kg/mm, 67.2 lb/in)
Spring stroke (K1)	0 - 64 mm (0 - 2.52 in)
Spring stroke (K2)	64 - 140 mm (2.52 - 5.51 in)
Optional spring available	No
Fork oil:
Recommended oil	Suspension oil “01” or equivalent
Quantity (each front fork leg)	435 cm 3 (15.3 Imp oz, 14.7 US oz)
Level (from the top of the inner tube, with the inner tube fully compressed, and without the fork spring)	140 mm (5.51 in)
Spring preload adjusting positions:
Minimum	5 (from fully turned out position)
Standard	2
Maximum	1
Rebound damping adjusting positions:
Minimum	17 (from fully turned-in position)
Standard	7
Maximum	1
Compression damping adjusting positions:
Minimum	21 (from fully turned-in position)
Standard	6
Maximum	1
Steering
Steering bearing type	Angular ball bearings
Lock to lock angle (left)	34°
Lock to lock angle (right)	34°
Rear suspension
Suspension type	Swingarm (link suspension)
Rear shock absorber assembly type	Coil spring/gas-oil damper
Rear shock absorber assembly travel	65 mm (2.56 in)
Spring:
Free length	182.5 mm (7.19 in)
Installed length	163 mm (6.42 in)
Spring rate (K1)	73.6 N/mm (7.5 kg/mm, 420 lb/in)
Spring stroke (K1)	0 - 65 mm (0 - 2.56 in)
Optional spring available	No
Standard spring preload gas/air pressure	1,200 kPa (12 kg/cm2, 170.7 psi)
Spring preload adjusting positions:
Minimum	1 (from fully turned-in position)
Standard	6
Maximum	11
Rebound damping adjusting positions:
Minimum	20 (from fully turned-in position)
Standard	10
Maximum	3
Compression damping adjusting positions:
Minimum	1 (from fully turned-in position)
Standard	7
Maximum	12
Swingarm
Free play (at the end of the swingarm):
Radial		1 mm (0.04 in)
Axial		1 mm (0.04 in)
Drive chain
Model (manufacturer)	50ZVM (DAIDO)
Link quantity	116
Drive chain slack	40 - 50 mm (1.57 - 1.97 in)
Maximum ten-link section	150.1 mm (5.91 in)	152.5 mm (6.00 in)

Electrical Specifications

Item	Standard	Limit
System voltage	12 V
Ignition system
Ignition system type	Transistorized coil ignition
Ignition timing	5° BTDC at 1,100 r/min
Advanced timing	55° BTDC at 5,000 r/min
Advancer type	Throttle position sensor and electrical
Pickup coil resistance/color	248 - 372 ohms/Gy-B
Transistorized coil ignition unit model (manufacturer)	TNDF69 (DENSO)
Ignition coils
Model (manufacturer)	J0313 (DENSO)
Minimum ignition spark gap	6 mm (0.24 in)
Primary coil resistance	1.87 - 2.53 ohms
Secondary coil resistance	12 - 18 k ohms
Spark plug caps
Material	Rubber
Resistance	10 k ohms
Throttle position sensor standard resistance	4 - 6 k ohms
Charging system
System type	AC magneto
Model (manufacturer)	F4T361 (MITSUBISHI)
Normal output	14 V / 365 W at 5,000 r/min
Stator coil resistance/color	0.27 - 0.33 ohms at 20°C (68°F)/W-W
Rectifier/regulator
Regulator type	Semiconductor short circuit
Model (manufacturer)	SH650C-11 (SHINDENGEN)
No-load regulated voltage	14.1 - 14.9 V
Rectifier capacity	18 A
Withstand voltage	200 V
Battery
Battery type	GT14B-4
Battery voltage/capacity	12 V / 12 AH
Specific gravity	1.320
Headlight type	Halogen bulb
Bulbs (voltage/wattage x quantity)
Headlight	12 V 60 W / 55 W x 2
Auxiliary light	12 V 5 W x 2
Tail/brake light	12 V 5 W / 21 W x 2
Front turn signal light	12 V 8 W / 27 W x 2
Rear turn signal light	12 V 27 W x 2
Meter light	12 V 2 W x 3
Indicator light (voltage/wattage x quantity)
Neutral indicator light	14 V 1.4 W x 1
High beam indicator light	14 V 1.4 W x 1
Oil level indicator light	14 V 1.4 W x 1
Turn signal indicator light	14 V 1.4 W x 2
Fuel indicator light	12 V 2 W x 1
Water temperature indicator light	LED
Electric starting system
System type	Constant mesh
Starter motor:
Model (manufacturer)	SM-13 (MITSUBA)
Power output	0.8 kW
Brushes:
Overall length	12.5 mm (0.49 in)	4 mm (0.16 in)
Spring force	7.65 - 10.01 N (780 - 1,021 gf, 27.5 - 36.0 oz)
Commutator resistance	0.025 - 0.035 ohms
Commutator diameter	28 mm (1.10 in)	27 mm (1.06 in)
Mica undercut	0.7 mm (0.03 in)
Starter relay
Model (manufacturer)	MS5F-631 (JIDECO)
Amperage	180 A
Coil resistance	4.18 - 4.62 ohms
Starting circuit cutoff relay
Model (manufacturer)	G8R-30YM (Omron)
Coil resistance	180 ohms +/- 10%
Headlight relay
Model (manufacturer)	G8H-1C4T-D-ST6-Y48 (Omron)
Coil resistance	80 ohms +/- 10%
Fuel pump relay
Coil resistance	180 ohms +/- 10%
Horn
Horn type	Plain
Model (manufacturer) x quantity	YF-12 (NIKKO) x 1
Max. amperage	3 A
Turn signal relay
Relay type	Full-transistor
Model (manufacturer)	FE246BH (DENSO)
Self-cancelling device built-in	No
Turn signal blinking frequency	75 - 95 cycles/min.
Wattage	27 W x 2 + 3.4 W
Oil level switch
Model (manufacturer)	5LV (DENSO)
Fuel sender
Model (manufacturer)	5LV (NIPPON SEIKI)
Resistance	4 - 100 ohms at 25°C (77°F)
Sidestand/fuel pump relay
Model (manufacturer)	5EB-20 (OMRON)
Coil resistance	180 ohms
Fuel pump maximum amperage	1.2 A
Radiator fan
Model (manufacturer)	4XV (TOYO RADIATOR)
Thermo switch
Model (manufacturer)	5JJ (NIPPON THERMOSTAT)
Fuses (amperage x quantity)
Main fuse	30 A x 1
Headlight fuse	20 A x 1
Signaling system fuse	20 A x 1
Ignition fuse	20 A x 1
Radiator fan fuse	10 A x 1
Turn signal relay fuse	10 A x 1
Backup fuse (odometer)	10 A x 1
Reserve fuse	30 A x 1
	20 A x 1
	10 A x 1

Engine Tightening Torques

				Tightening Torque
Item	Fastener	Thread Size	Q'ty	Nm	m-Kg	lb-ft
Spark plugs		M10	4	13	1.3	9.4
Cylinder head	Nut	M10	8	50	5.0	36
Cylinder head	Cap nut	M10	2	50	5.0	36
Cylinder head	Bolt	M6	2	12	1.2	8.7
Camshaft caps	Bolt	M6	28	10	1.0	7.2
Cylinder head cover	Bolt	M6	6	12	1.2	8.7
Cylinder head (exhaust pipe)	Stud Bolt	M8	8	15	1.5	11
Connecting rod caps	Nut	M8	8	36	3.6	25
Generator rotor	Bolt	M10	1	65 + 60°	6.5 + 60°	47 + 60°
Crankshaft sprocket	Bolt	M10	1	60	6.0	43
Cap Bolt (timing chain tensioner)	Bolt	M6	1	6.4	0.64	4.6
Camshaft sprocket	Bolt	M7	4	24	2.4	17
Water pump inlet pipe	Bolt	M6	1	10	1.0	7.2
Water pump outlet pipe	Bolt	M6	1	10	1.0	7.2
Oil/water pump assembly driven sprocket	Bolt	M6	1	15	1.5	11
Oil pump	Bolt	M6	1	12	1.2	8.7
Oil cooler	Bolt	M20	1	35	3.5	25
Engine oil drain Bolt	Bolt	M14	1	43	4.3	31
Oil strainer housing	Bolt	M6	2	10	1.0	7.2
Oil/water pump assembly driven sprocket cover	Bolt	M6	1	12	1.2	8.7
Oil delivery pipe	Bolt	M6	1	10	1.0	7.2
Oil filter Bolt	Bolt	M20	1	70	7.0	51
Oil filter cartridge		M20	1	17	1.7	12
Oil pipe	Bolt	M6	2	10	1.0	7.2
Oil strainer cover	Bolt	M6	2	10	1.0	7.2
Air cleaner cap and air cleaner	Screw	M6	4	6	0.6	4.3
Frame and air cleaner	Bolt	M6	3	7	0.7	5.1
Air cleaner cover and air cleaner	Screw	M6	6	2	0.2	1.4
Ring nut and cylinder head	Nut	M8	8	20	2.0	14
Exhaust pipe and muffler	Bolt	M8	3	20	2.0	14
Emission check Bolt	Bolt	M8	4	10	1.0	7.2
EXUP pulley cover	Bolt	M6	3	10	1.0	7.2
EXUP cable bracket	Bolt	M6	3	10	1.0	7.2
EXUP pulley and shaft arm	Bolt	M5	1	10	1.0	7.2
Exhaust joint	Bolt	M4	2	3	0.3	2.2
Exhaust pipe assembly	Bolt	M8	1	20	2.0	14
Air induction system pipe	Band		4	3.5	0.35	2.5
Crankcase (cylinder head)	Stud Bolt	M10	10	10	1.0	7.2
Crankcase	Bolt	M9	10	See Note	See Note	See Note
Crankcase	Bolt	M6	2	14	1.4	10
Crankcase	Bolt	M6	14	12	1.2	8.7
Crankcase	Bolt	M8	2	24	2.4	17
AC magneto cover	Bolt	M6	9	12	1.2	8.7
Drive sprocker cover	Bolt	M6	4	10	1.0	7.2
Plate	Bolt	M6	2	10	1.0	7.2
Clutch cover	Bolt	M6	8	12	1.2	8.7
Timing chain cap Bolt	Bolt	M6	8	12	1.2	8.7
Shift shaft cover	Bolt	M6	5	12	1.2	8.7
Breather plate	Bolt	M6	5	10	1.0	7.2
Timing mark accessing screw	Bolt	M8	1	15	1.5	11
Starter clutch idle gear shaft	Bolt	M6	1	10	1.0	7.2
Starter one-way clutch	Bolt	M6	3	12	1.2	8.7
Clutch boss (use lock washer)	Nut	M20	1	90	9.0	65
Clutch spring	Bolt	M6	6	8	0.8	5.8
Drive sprocket (use lock washer)	Nut	M22	1	85	8.5	61
Main axle bearing housing	Screw	M6	3	12	1.2	8.7
Shift lever stopper	Bolt	M6	2	10	1.0	7.2
Stopper screw	Screw	M8	1	22	2.2	16
Shift rod (left thread)	Nut	M6	1	6.5	0.65	4.7
Shift rod	Nut	M6	2	6.5	0.65	4.7
Shift rod joint	Bolt	M6	1	10	1.0	7.2
Shift arm	Bolt	M6	1	10	1.0	7.2
AC magneto stator coil	Screw	M6	3	14	1.4	10
Ignitor unit	Screw	M5	2	7	1.0	7.2
Neutral switch		M10	1	20	2.0	14
Pick up coil	Bolt	M6	2	10	1.0	7.2
Thermo unit		NPT 1/8"	1	15	1.5	11

Note:

1. First, tighten the bolt to approximately 14.7 Nm (1.5 m-Kg, 11 lb-ft) with a torque wrench

2. Tighten another 45 - 50°

Chassis Tightening Torques

		Tightening Torque
Item	Thread Size	Nm	m-Kg	lb-ft
Upper bracket pinch bolt	M8	30	3.0	22
Upper bracket cap nut	M22	110	11	80
Upper bracket and handlebar holder	M10	32	3.2	23
Handlebar holder	M8	23	2.3	17
Lower bracket pinch bolt		23	2.3	17
Lower bracket ring nut (See Note)	M25	18	1.8	13
Front brake master cylinder	M6	10	1.0	7.2
Front brake hose union bolt	M10	30	3.0	22
Engine Mounting:
Engine mounting bolt/nut	M10	55	5.5	40
Engine mounting bolt/nut	M8	33	3.3	24
Frame and down tube	M10	89	8.9	64
Clutch cable lock nut	M8	7	0.7	5.1
Ignition coil and stay	M6	7	0.7	5.1
Pivot shaft	M18	125	12.5	90
Rear shock absorber (upper)	M10	40	4.0	29
Rear shock absorber and relay arm	M10	40	4.0	29
Relay arm and frame	M10	40	4.0	29
Relay arm and connecting arm	M12	48	4.8	35
Connecting arm and swing arm	M12	48	4.8	35
Drive chain guard	M6	7	0.7	5.1
Drive chain case	M6	7	0.7	5.1
Fuel cock	M6	7	0.7	5.1
Fuel sender	M5	4	0.4	2.9
Side cover	M6	4	0.4	2.9
Coolant reservoir tank	M6	4	0.4	2.9
Front wheel axle	M16	72	7.2	52
Front wheel axle pinch bolt	M8	23	2.3	17
Front brake caliper	M10	40	4.0	29
Front brake disk	M6	18	1.8	13
Front brake bleed screw	M8	6	0.6	4.3
Rear brake torque rod	M8	23	2.3	17
Rear wheel sprocket	M10	69	6.9	50
Drive chain adjusting nut	M8	16	1.6	12
Rear brake caliper	M10	40	4.0	29
Rear wheel axle	M24	150	15	108
Rear brake hose union bolt	M10	30	3.0	22
Rear brake bleed screw	M8	6	0.6	4.3
Rear brake disk	M8	23	2.3	17
Rider footrest bracket and frame	M8	30	3.0	22
Rear brake reservoir tank	M6	4	0.4	2.9
Rear brake master cylinder	M8	23	2.3	17
Rider footrest and bracket	M10	55	5.5	40
Passenger footrest bracket and frame	M8	28	2.8	20
Passenger footrest bracket and muffler	M10	48	4.8	35

Note:

1. First, tighten the ring nut to approximately 52 Nm (5.2 m-Kg, 38 lb-ft) with a torque wrench

2. Loosen the ring nut completely

3. Retighten the ring nut to specification

Last Updated: 05-30-2002