Cooling system specifications

 

ITEM	SPECIFICATIONS
Coolant capacity		Radiator and engine	1.02 liters (1.08 US qt, 0.90 Imp qt)
		At draining	0.74 liter (0.78	US qt, 0.65	Imp qt)
		Reserve tank	0.16 liter (0.17	US qt, 0.14	Imp qt)
Radiator cap relief pressure			93.2 – 122.6 kPa (0.95 –	1.25 kgf/cm^2, 13.5 – 17.8 psi)
Thermostat		Begin to open	81 – 84°C (178 – 183°F)
		Fully open	95°C (203°F)
		Valve lift	4.5 mm (0.18 in) minimum
Recommended coolant			High quality ethylene glycol antifreeze containing silicate-free
			corrosion inhibitors
Standard coolant concentration		1:1 (mixture with distilled water)

 

CYLINDER HEAD/VALVES SPECIFICATIONS

 

							Unit: mm (in)
		ITEM			STANDARD	SERVICE LIMIT
Cylinder compression at 490 min^-1 (rpm)		1,294 kPa (13.2 kgf/cm^2, 188 psi)	–
Valve clearance			IN	0.16 ± 0.03 (0.006 ± 0.001)	–
				EX	0.27 ± 0.03 (0.011 ± 0.001)	–
Valve, valve		Valve stem O.D.		IN	4.475 – 4.490 (0.1762 – 0.1768)	4.46 (0.176)
guide
			EX	4.465 – 4.480 (0.1758 – 0.1764)	4.45 (0.175)
		Valve guide I.D.		IN/EX	4.500	– 4.512 (0.1772 – 0.1776)	4.540 (0.1787)
		Stem-to-guide		IN	0.010	– 0.037 (0.0004 – 0.0015)	0.07 (0.003)
		clearance
			EX	0.020 – 0.047 (0.0008 – 0.0019)	0.08 (0.003)
		Valve guide height		IN/EX	13.8 – 14.0 (0.54 – 0.55)	–
		Valve seat width		IN/EX	0.90 – 1.10 (0.035 – 0.043)	1.50 (0.059)
Valve spring		Free length		Inner	34.58	(1.361)	32.85 (1.293)
				Outer	40.37	(1.589)	38.35 (1.510)
Rocker arm,		Arm I.D.		IN/EX	10.000 – 10.015 (0.3937 – 0.3943)	10.10 (0.398)
rocker arm
	Shaft O.D.		IN/EX	9.972	– 9.987 (0.3926 – 0.3932)	9.91 (0.390)
shaft
	Arm-to-shaft		IN/EX	0.013	– 0.043 (0.0005 – 0.0017)	0.10 (0.004)
		clearance
Camshaft		Cam lobe height		IN	30.931 – 31.171 (1.2178 – 1.2272)	30.911 (1.2170)
				EX	30.839 – 31.079 (1.2141 – 1.2236)	30.819 (1.2133)
		Camshaft journal O.D.		19.959 – 19.980 (0.7858 – 0.7866)	–
		Oil clearance		0.020	– 0.062 (0.0008 – 0.0024)	0.10 (0.004)
Cylinder		Camshaft journal area I.D.	20.000 – 20.021 (0.7874 – 0.7882)	–
head
	Warpage			–	0.05 (0.002)

 

CYLINDER/PISTON SPECIFICATIONS

 

				Unit: mm (in)
	ITEM		STANDARD	SERVICE LIMIT
Cylinder	I.D.		76.000 – 76.010 (2.9921 – 2.9925)	76.04 (2.994)
	Out-of-round		–	0.010 (0.0004)
	Taper		–	0.010 (0.0004)
	Warpage		–	0.05 (0.002)
Piston, piston	Piston O.D. at 11 mm (0.4 in) from	75.960 – 75.980 (2.9905 – 2.9913)	75.89 (2.988)
pin, piston	bottom
ring
Piston pin hole I.D.		17.002 – 17.008 (0.6694 – 0.6696)	17.030 (0.6705)
	Piston pin O.D.		16.994 – 17.000 (0.6691 – 0.6693)	16.980 (0.6685)
	Piston-to-piston pin clearance	0.002 – 0.014 (0.0001 – 0.0006)	0.02 (0.001)
	Piston ring end	Top	0.28 – 0.38 (0.011 – 0.015)	0.40 (0.016)
	gap
	Second	0.40 – 0.55 (0.016 – 0.022)	0.70 (0.028)
		Oil (side rail)	0.20 – 0.70 (0.008 – 0.028)	1.10 (0.043)
	Piston ring-to-ring	Top	0.040 – 0.080 (0.0016 – 0.0031)	0.10 (0.004)
	groove clearance
	Second	0.015 – 0.050 (0.0006 – 0.0020)	0.09 (0.004)
Cylinder-to-piston clearance		0.020 – 0.050 (0.0008 – 0.0020)	0.09 (0.004)
Connecting rod small end I.D.		17.016 – 17.034 (0.6699 – 0.6706)	17.06 (0.672)
Connecting rod-to-piston pin clearance		0.016 – 0.040 (0.0006 – 0.0016)	0.10 (0.004)

 

 

1-6

						GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS
									Unit: mm (in)
	ITEM			STANDARD		SERVICE LIMIT
Clutch lever freeplay				10 – 20 (0.4 – 0.8)			–
Clutch	Spring free length			41.5 (1.63)		37.5 (1.48)
	Disc thickness		Disc A/B	2.30 – 2.50 (0.091 – 0.098)		2.27 (0.089)
	Plate warpage		Plate A/B	–		0.30 (0.012)
Clutch outer guide I.D.				20.000 – 20.021 (0.7874 – 0.7882)		20.04 (0.789)
Mainshaft O.D. at clutch outer guide			19.967 – 19.980 (0.7861 – 0.7866)		19.947 (0.7853)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
									Unit: mm (in)
	ITEM			STANDARD		SERVICE LIMIT
Starter driven gear		I.D.			34.000 – 34.013 (1.3386 – 1.3391)		34.033 (1.3399)
			O.D.			51.705 – 51.718 (2.0356 – 2.0361)		51.685 (2.0348)
CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SPECIFICATIONS
									Unit: mm (in)
	ITEM			STANDARD		SERVICE LIMIT
Crankshaft	Runout				–		0.03 (0.001)
	Connecting rod big end radial clearance	0.004 – 0.016 (0.0002 – 0.0006)		0.05 (0.002)
	Connecting rod big end side clearance	0.05 – 0.50 (0.002 – 0.020)		0.85 (0.033)
	Main journal oil clearance	0.018 – 0.045 (0.0007 – 0.0018)		0.075	(0.0030)
	Main journal O.D.			33.985 – 34.000 (1.3380 – 1.3386)		33.975 (1.3376)
Main journal bearing support I.D.			38.000 – 38.018 (1.4961 – 1.4968)		38.036 (1.4975)
Transmission	Gear I.D.		M5, M6	23.000 – 23.021 (0.9055 – 0.9063)		23.07	(0.908)
				C1	23.020 – 23.041 (0.9063 – 0.9071)		23.09	(0.909)
				C2	25.000 – 25.021 (0.9843 – 0.9851)		25.04	(0.986)
				C3, C4	28.000 – 28.021 (1.1024 – 1.1032)		28.04	(1.104)
	Bushing O.D.	M5, M6	22.959 – 22.980 (0.9039 – 0.9047)		22.91	(0.902)
				C1	22.984 – 23.005 (0.9049 – 0.9057)		22.47	(0.885)
				C2	24.959 – 24.980 (0.9826 – 0.9835)		24.90	(0.980)
				C3, C4	27.959 – 27.980 (1.1007 – 1.1016)		27.95	(1.100)
	Gear-to-bushing	M5, M6, C2,	0.020 – 0.062 (0.0008 – 0.0024)		0.10 (0.004)
	clearance		C3, C4
				C1	0.015 – 0.057 (0.0006 – 0.0022)		0.10 (0.004)
	Bushing I.D.		M5, C1	20.000 – 20.021 (0.7874 – 0.7882)		20.05	(0.789)
				C2	22.000 – 22.021 (0.8661 – 0.8670)		22.07	(0.869)
				C3	25.000 – 25.021 (0.9843 – 0.9851)		25.04	(0.986)
	Mainshaft /		at M5 bushing	19.959 – 19.980 (0.7858 – 0.7866)		19.91	(0.784)
	countershaft O.D.
	at C1 bushing	19.959 – 19.980 (0.7858 – 0.7866)		19.91	(0.784)
				at C2 bushing	21.959 – 21.980 (0.8645 – 0.8654)		21.91	(0.863)
				at C3 bushing	24.959 – 24.980 (0.9826 – 0.9835)		24.90	(0.980)
	Bushing-to-shaft	M5, C1, C2, C3	0.020 – 0.062 (0.0008 – 0.0024)		0.10 (0.004)
	clearance
Shift fork,	Shift fork shaft O.D.			11.957 – 11.968 (0.4707 – 0.4712)		11.95	(0.470)
shift fork
Shift fork I.D.			12.000 – 12.018 (0.4724 – 0.4731)		12.05	(0.474)
shaft
Shift fork claw thickness	4.93 – 5.00 (0.194 – 0.197)		4.82 (0.190)
Shift drum	Shift drum O.D.	Left side	13.966 – 13.984 (0.5498 – 0.5506)		13.94	(0.549)
	Shift drum journal	Left side	14.000 – 14.027 (0.5512 – 0.5522)		14.06	(0.554)
	I.D.
	Shift drum-to-shift
	drum journal		Left side	0.016 – 0.061 (0.0006 – 0.0024)		0.08 (0.003)
	clearance

 

 

1-7

GENERAL INFORMATION

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

 

				Unit: mm (in)
	ITEM		STANDARD	SERVICE LIMIT
Minimum tire thread depth		–	3.0 (0.12)
Cold tire pressure	Driver only		150 kPa (1.50 kgf/cm^2, 22 psi)	–
	Driver and passenger	150 kPa (1.50 kgf/cm^2, 22 psi)	–
Axle runout			–	0.2 (0.01)
Wheel rim runout	Radial		–	2.0 (0.08)
	Axial		–	2.0 (0.08)
Wheel hub-to-rim distance		23.45 ± 1.0 (0.92 ± 0.04)	–
Fork	Spring free length (Right side only)	575.0 (22.64)	–
	Pipe runout		–	0.20 (0.008)
	Recommended fork fluid	Honda ULTRA CUSHION OIL 10W or	–
			equivalent
	Fluid level	Right	122 (4.8)	–
		Left	38 (1.5)
	Fluid capacity	Right	658 ± 2.5 cm^3	–
			(22.3 ± 0.08 US oz, 23.2 ± 0.09 Imp oz)
		Left	683 ± 2.5 cm^3
			(23.1 ± 0.08 US oz, 24.0 ± 0.09 Imp oz)
Steering head bearing	pre-load		10.6 – 21.2 N	–
			(1.08 – 2.16 kgf, 2.38 – 4.77 lbf)

 

REAR WHEEL/SUSPENSION SPECIFICATIONS

 

			Unit: mm (in)
ITEM	STANDARD	SERVICE LIMIT
Minimum tire thread depth		–	3.0 (0.12)
Cold tire pressure	Driver only	150 kPa (1.50 kgf/cm^2, 22 psi)	–
	Driver and passenger	150 kPa (1.50 kgf/cm^2, 22 psi)	–
Axle runout		–	0.2 (0.01)
Wheel rim runout	Radial	–	2.0 (0.08)
	Axial	–	2.0 (0.08)
Wheel hub-to-rim distance		26.9 ± 1.0 (1.06 ± 0.04)	–
Drive chain	Size/link	DID520VF-106LE	–
	Slack	25 – 35 (1.0 – 1.4)	–

 

BRAKE SYSTEM SPECIFICATIONS

 

			Unit: mm (in)
	ITEM	STANDARD	SERVICE LIMIT
Front	Specified brake fluid	DOT 3 or DOT 4	–
	Brake pad wear indicator	–	To groove
	Brake disc thickness	3.3 – 3.7 (0.13 – 0.15)	3.0 (0.12)
	Brake disc warpage	–	0.3 (0.01)
	Master cylinder I.D.	12.700 – 12.743 (0.5000 – 0.5017)	12.755 (0.5022)
	Master piston O.D.	12.657 – 12.684 (0.4983 – 0.4994)	12.645 (0.4978)
	Caliper cylinder I.D.	27.000 – 27.050 (1.0630 – 1.0650)	27.060 (1.0654)
	Caliper piston O.D.	26.935 – 26.968 (1.0604 – 1.0617)	26.89 (1.0587)
Rear	Specified brake fluid	DOT 3 or DOT 4	–
	Brake pad wear indicator	–	To groove
	Brake disc thickness	4.3 – 4.7 (0.17 – 0.19)	4.0 (0.16)
	Brake disc warpage	–	0.3 (0.01)
	Master cylinder I.D.	12.700 – 12.743 (0.5000 – 0.5017)	12.755 (0.5022)
	Master piston O.D.	12.657 – 12.684 (0.4983 – 0.4994)	12.645 (0.4978)
	Caliper cylinder I.D.	27.000 – 27.050 (1.0630 – 1.0650)	27.060 (1.0654)
	Caliper piston O.D.	26.935 – 26.968 (1.0604 – 1.0617)	26.89 (1.0587)
	Brake pedal height	64 – 65 (2.52 – 2.56)	–

 

 

1-8

					GENERAL INFORMATION
BATTERY/CHARGING SYSTEM SPECIFICATIONS
	ITEM			SPECIFICATIONS
Battery	Type			YTX7L-BS
	Capacity			12 V - 6 Ah (10 HR)
	Current leakage			0.34 mA max.
	Voltage		Fully charged		13.0 – 13.2 V
	(20°C/68°F)
		Needs		Below 12.3 V
			charging
	Charging current		Normal		0.6 A/5 – 10 h
			Quick		3 A/1 h
Alternator	Capacity				0.34 kW/5,000 min^-1 (rpm)
	Charging coil resistance (20°C/68°F)		0.1 – 1.0 Ω
LIGHTS/METERS/SWITCHES SPECIFICATIONS
	ITEM			SPECIFICATION
Bulbs	Headlight			12 V - 60/55 W
	Position light			12 V - 5 W
	Brake/taillight			12 V - 21/5 W
	Front turn signal light			12 V - 21 W x 2
	Rear turn signal light			12 V - 21 W x 2
	Instrument light			LED
	Turn signal indicator			LED
	High beam indicator			LED
	Neutral indicator			LED
	MIL			LED
Fuse	Main fuse			30 A
	Sub fuse			10 A x 5, 5 A x 1

 

TORQUE VALUES

 

STANDARD TORQUE VALUES

 

FASTENER TYPE	TORQUE	FASTENER TYPE	TORQUE
N·m (kgf·m, lbf·ft)	N·m (kgf·m, lbf·ft)
5 mm bolt and nut	5.2	(0.5,	3.8)	5 mm screw	4.2	(0.4,	3.1)
6 mm bolt and nut	10 (1.0, 7)	6 mm screw	9.0	(0.9,	6.6)
(Include SH flange bolt)
			6 mm flange bolt (8 mm head, large
8 mm bolt and nut		(2.2,	16)	flange) and nut	12 (1.2, 9)
10 mm bolt and nut		(3.5,	25)	8 mm flange bolt and nut		(2.8,	20)
12 mm bolt and nut		(5.5,	40)	10 mm flange bolt and nut		(4.0,	29)

 

 

1-9

GENERAL INFORMATION

ENGINE & FRAME TORQUE VALUES

 

• Torque specifications listed below are for important fasteners.

• Others should be tightened to standard torque values listed above.

 

FRAME/BODY PANELS/EXHAUST SYSTEM
ITEM		Q'TY	THREAD	TORQUE	REMARKS
	DIA. (mm)	N·m (kgf·m, lbf·ft)
Hook bolt					(2.1, 15)
Left side cover assembly screw				0.9	(0.1, 0.7)
Right fuel tank shroud assembly screw				0.9	(0.1, 0.7)
Left fuel tank shroud assembly screw				0.9	(0.1, 0.7)
Headlight cowl mounting bolt				8.5	(0.9, 6.3)
Rear side reflector mounting nut (U type				1.5	(0.2, 1.1)	U-nut
only)
Rear reflector mounting nut				1.5	(0.2, 1.1)	U-nut
Brake/taillight mounting screw				4.5	(0.5, 3.3)
Exhaust pipe protector socket bolt				12 (1.2, 9)
Muffler protector cover screw				1.5	(0.2, 1.1)
Muffler front mounting bolt					(3.3, 24)
Muffler band bolt				22.5 (2.3, 17)
Exhaust pipe joint nut					(1.8, 13)
Exhaust pipe stud bolt					–	See page 2-11
Air cleaner connecting hose band screw				1.5	(0.2, 1.1)
Sub-frame upper mounting nut					(2.8, 20)
Sub-frame lower mounting bolt					(2.8, 20)
Rear master cylinder reservoir mounting				10 (1.0, 7)
bolt
Sidestand pivot bolt				10 (1.0, 7)	See page 2-14
Sidestand pivot lock nut					(3.1, 22)	U-nut, See page 2-14
MAINTENANCE
ITEM		Q'TY	THREAD	TORQUE	REMARKS
	DIA. (mm)	N·m (kgf·m, lbf·ft)
Throttle cable A adjuster lock nut (throttle
body side)				3.0	(0.3, 2.2)
Air cleaner cover screw				1.2	(0.1, 0.9)
Spark plug					(1.6, 12)
Crankshaft hole cap				8.0	(0.8, 5.9)	Apply engine oil to the
						threads.
Timing hole cap				6.0	(0.6, 4.4)	Apply engine oil to the
						threads.
Engine oil drain bolt					(2.4, 18)
Drive chain adjuster lock nut					(2.8, 20)	UBS nut
Rear axle nut					(9.0, 65)	U-nut
Drive sprocket fixing plate bolt				10 (1.0, 7)
Driven sprocket nut					(5.1, 37)	U-nut
Rear master cylinder reservoir mounting				10 (1.0, 7)
bolt
Master cylinder reservoir cover screw				1.5	(0.2, 1.1)
Rear master cylinder push rod lock nut				17.2 (1.8, 13)
Front spoke			BC 3.2	3.7	(0.4, 2.7)
Rear spoke			BC 3.2	3.7	(0.4, 2.7)
PGM-FI SYSTEM
ITEM		Q'TY	THREAD	TORQUE	REMARKS
	DIA. (mm)	N·m (kgf·m, lbf·ft)
Sensor unit torx screw				3.4	(0.3, 2.5)
ECT sensor					(2.5, 18)
O2 sensor					(2.5, 18)
Bank angle sensor mounting nut				9.0	(0.9, 6.6)

 

1-10

					GENERAL INFORMATION
IGNITION SYSTEM
ITEM	Q'TY	THREAD	TORQUE		REMARKS
DIA. (mm)	N·m (kgf·m, lbf·ft)
Timing hole cap			6.0	(0.6, 4.4)		Apply engine oil to the
						threads.
ELECTRIC STARTER
ITEM	Q'TY	THREAD	TORQUE		REMARKS
DIA. (mm)	N·m (kgf·m, lbf·ft)
Negative brush screw			3.7	(0.4, 2.7)
Starter motor assembly bolt			4.9	(0.5, 3.6)
FUEL SYSTEM
ITEM	Q'TY	THREAD	TORQUE		REMARKS
DIA. (mm)	N·m (kgf·m, lbf·ft)
Fuel pump mounting nut			12 (1.2, 9)		For tightening sequence
						(page 7-9).
Air cleaner housing mounting bolt			7.0	(0.7, 5.2)
Insulator band screw			4.2	(0.4, 3.1)		See page 7-13
Air cleaner connecting hose band screw			1.5	(0.2, 1.1)
Throttle cable stay screw			3.4	(0.3, 2.5)
Clamp stay screw			3.4	(0.3, 2.5)
Throttle cable A joint nut (grip side)			1.5	(0.2, 1.1)
Throttle cable B joint nut (grip side)			1.5	(0.2, 1.1)
Throttle cable B nut (throttle body side)			3.0	(0.3, 2.2)
Injector joint mounting bolt			5.1	(0.5, 3.8)
IACV setting plate torx screw			2.1	(0.2, 1.5)
PAIR check valve cover bolt			5.2	(0.5, 3.8)
COOLING SYSTEM
ITEM	Q'TY	THREAD	TORQUE		REMARKS
DIA. (mm)	N·m (kgf·m, lbf·ft)
Water hose band screw		–		–		See page 9-7
Fan motor shroud mounting bolt			8.5	(0.9, 6.3)
Fan motor screw			2.7	(0.3, 2.0)
Cooling fan nut			1.0	(0.1, 0.7)		Apply locking agent to the
						threads.
Water pump impeller			10 (1.0, 7)
CYLINDER HEAD/VALVES
ITEM	Q'TY	THREAD	TORQUE		REMARKS
DIA. (mm)	N·m (kgf·m, lbf·ft)
Cylinder head cover bolt			10 (1.0, 7)
Camshaft holder mounting bolt			12 (1.2, 9)		Apply engine oil to the threads
						and seating surface.
Cylinder head mounting nut				(4.6, 33)		Apply engine oil to the threads
						and seating surface.
Cam chain tensioner lifter plug			4.2	(0.4, 3.1)
CYLINDER/PISTON
ITEM	Q'TY	THREAD	TORQUE		REMARKS
DIA. (mm)	N·m (kgf·m, lbf·ft)
Cylinder stud bolt				–		See page 11-4
Cam chain tensioner lifter plug			4.2	(0.4, 3.1)

 

1-11

GENERAL INFORMATION

CLUTCH/GEARSHIFT LINKAGE
ITEM	Q'TY	THREAD	TORQUE	REMARKS
DIA. (mm)	N·m (kgf·m, lbf·ft)
Clutch center lock nut			108 (11.0, 80)	Lock nut; replace with a new
				one and stake.
				Apply engine oil to the threads
				and seating surface.
Clutch lifter plate bolt			12 (1.2, 9)
Shift drum stopper plate bolt			10 (1.0, 7)	Apply locking agent to the
				threads.
Shift drum stopper arm bolt			10 (1.0, 7)	Apply locking agent to the
				threads.
Gearshift spindle return spring pin			30 (3.1, 22)	Apply locking agent to the
				threads.
Primary drive gear lock nut			108 (11.0, 80)	Apply engine oil to the threads
				and seating surface.
ALTERNATOR/STARTER CLUTCH
ITEM	Q'TY	THREAD	TORQUE	REMARKS
DIA. (mm)	N·m (kgf·m, lbf·ft)
Stator mounting socket bolt			10 (1.0, 7)
CKP sensor mounting socket bolt			10 (1.0, 7)	Apply locking agent to the
				threads.
				Coating width: 6.5 ± 1.0 mm
				(0.26 ± 0.04 in) from tip
Flywheel bolt			128 (13.1, 94)	Apply engine oil to the threads
				and seating surface.
Starter clutch socket bolt			30 (3.1, 22)	Apply locking agent to the
				threads.
CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
ITEM	Q'TY	THREAD	TORQUE	REMARKS
DIA. (mm)	N·m (kgf·m, lbf·ft)
Balancer shaft nut			44 (4.5, 32)	Apply engine oil to the threads
				and seating surface.
Cam chain tensioner pivot bolt			10 (1.0, 7)	Apply locking agent to the
				threads.
				Coating width: 6.5 ± 1.0 mm
				(0.26 ± 0.04 in) from tip
ENGINE REMOVAL/INSTALLATION
ITEM	Q'TY	THREAD	TORQUE	REMARKS
DIA. (mm)	N·m (kgf·m, lbf·ft)
Rear engin