ANUAL SERVICE M
LIGHTS/METER/SWITCHES SPECIFICATIONS
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ITEM
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SPECIFICATIONS
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|
Headlight
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12 V-35 W
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Tail light
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LED
|
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Fuse
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15 A
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STANDARD TORQUE VALUES
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FASTENER TYPE
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TORQUE N-m (kgf-m, Ibf-ft)
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FASTENER TYPE
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TORQUE N m (kgf-m, Ibf ft)
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5 mm hex bolt and nut
6 mm hex bolt and nut 8 mm hex bolt and nut 10 mm hex bolt and nut 12 mm hex bolt and nut
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5.2 (0.5, 3.8) 10(1.0, 7) 22 (2.2, 16) 34 (3.5, 25) 54 (5.5, 40)
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5 mm screw
6 mm screw
6 mm flange bolt (8 mm head)
6 mm flange bolt (10 mm head) and nut 8 mm flange bolt and nut 10 mm flange bolt and nut
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4.2 (0.4, 3.1)
9.0 (0.9, 6.6)
9.0 (0.9, 6.6)
12 (1.2, 9) 27 (2.8, 20) 39 (4.0, 29)
|
ENGINE & FRAME TORQUE VALUES
• Torque specifications listed below are for specified fasteners.
• Others should be tightened to standard torque values listed above.
NOTE:
1. Apply oil to the threads and seating surface.
2. Apply locking agent to the threads.
3. Stake.
4. U-nut
5. ALOC bolt/screw; replace with new one.
6. Loosen the bolt 1/8 to 1/4 turns after tightening it to the specified torque, then tighten the pivot nut.
7. Apply grease to the threads.
8. UBS nut
9. After '07: Apply molybdenum disulfide grease (TB1901 or equivalent) to the threads.
10. Apply Honda Hondalock 3 or equivalent high strength locking agent to the threads.
ENGINE
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MAINTENANCE
|
ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE N-m (kgf-m, Ibf ft)
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REMARKS
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|
Engine oil drain bolt
|
|
1
|
8
|
16(1.6, 12)
|
NOTE 1
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|
Transmission oil drain bolt
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|
1
|
8
|
16(1.6,12)
|
NOTE 1
|
|
Transmission oil check bolt
|
|
1
|
6
|
10(1.0,7)
|
|
|
Crankshaft hole cap
|
|
1
|
30
|
15(1.5, 11)
|
NOTE 7
|
|
Decompressor adjuster lock nut
|
('05 - '07)
|
1
|
5
|
10(1.0,7)
|
NOTE 1
|
|
Spark plug
|
|
1
|
14
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22 (2.2, 16)
|
|
|
|
LUBRICATION SYSTEM
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ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE N-m (kgf-m, Ibf ft)
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REMARKS
|
|
Oil jet mounting bolt
|
1
|
6
|
10(1.0,7)
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NOTE 2
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|
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FUEL SYSTEM
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ITEM
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Q’TY
|
THREAD DIA. (mm)
|
TORQUE N m (kgf-m, Ibfft)
|
REMARKS
|
|
Throttle drum cover bolt
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|
1
|
5
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3.4 (0.3, 2.5)
|
|
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Needle jet
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|
1
|
7
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1.8 (0.2, 1.3)
|
|
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Main jet
|
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1
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5
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1.5 (0.2, 1.1)
|
|
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Slow jet
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|
1
|
10
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1.5 (0.2, 1.1)
|
|
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Slow air jet
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('05-'07)
|
1
|
5
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0.9 (0.1, 0.7)
|
|
|
Starter jet
|
|
1
|
5
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1.5 (0.2, 1.1)
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|
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Acc. pump bypass
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|
1
|
4
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0.3 (0.03, 0.2)
|
|
|
Carburetor top cover bolt
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|
|
4
|
2.1 (0.2, 1.5)
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|
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Throttle shaft screw
|
('05, '06)
|
1
|
4
|
2.1 (0.2, 1.5)
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NOTE 2
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|
Throttle shaft torx screw
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(After '06)
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1
|
4
|
2.1 (0.2, 1.5)
|
NOTE 2
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|
Float chamber screw
|
|
|
4
|
2.1 (0.2, 1.5)
|
|
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Accelerator pump cover screw
|
|
|
4
|
2.1 (0.2, 1.5)
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|
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Carburetor drain plug
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|
1
|
18
|
4.9 (0.5, 3.6)
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|
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Carburetor drain screw
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(After '05)
|
1
|
6
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1.5 (0.2, 1.1)
|
|
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Choke valve lock nut
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|
1
|
12
|
2.1 (0.2, 1.5)
|
|
|
Hot start valve lock nut
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|
1
|
12
|
2.1 (0.2, 1.5)
|
|
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Needle holder
|
|
1
|
8
|
2.1 (0.2, 1.5)
|
|
|
Throttle position sensor torx screw
|
('05, '06)
|
1
|
5
|
3.4 (0.3, 2.5)
|
|
|
Throttle position sensor bolt
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(After '06)
|
1
|
5
|
3.4 (0.3, 2.5)
|
|
|
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COOLING SYSTEM
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ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE Nm {kgf-m, Ibf ft)
|
REMARKS
|
|
Water pump impeller
|
1
|
7
|
12(1.2, 9)
|
|
|
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ENGINE REMOVAL/INSTALLATION
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ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE N m (kgf-m, Ibf ft)
|
REMARKS
|
|
Drive sprocket bolt
|
1
|
8
|
31 (3.2, 23)
|
|
|
|
CYLINDER HEAD/VALVES
|
ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE Nm (kgf-m, Ibf ft)
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REMARKS
|
|
Cylinder head cover bolt
|
|
3
|
6
|
10(1.0,7)
|
|
|
Camshaft holder mounting bolt
|
|
4
|
6
|
14(1.4, 10)
|
NOTE 1
|
|
Decompressor lifter arm mounting
|
|
|
|
|
|
|
nut
|
('05-'07)
|
1
|
8
|
22 (2.2, 16)
|
NOTE 1
|
|
Decompressor cam mounting bolt
|
('05-'07)
|
1
|
8
|
24(2.4, 18)
|
NOTE 1
|
|
Cylinder head nut
|
|
4
|
10
|
66 (6.7, 49)
|
NOTE 1
|
|
Cam sprocket bolt
|
|
2
|
7
|
20 (2.0, 15)
|
NOTE 2
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|
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CYLINDER/PISTON
|
ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE N-m (kgf-m, Ibf ft)
|
REMARKS
|
|
Cam chain tensioner lifter mounting bolt
|
2
|
6
|
12 (1.2, 9)
|
|
|
Cylinder stud bolt
|
|
4
|
-
|
-
|
See page 1-17
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|
|
CLUTCH/STARTER CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
|
ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE N-m (kgf m, Ibf ft)
|
REMARKS
|
|
Gearshift drum center pin
|
1
|
8
|
22 (2.2, 16)
|
NOTE 2
|
|
Gearshift drum stopper arm bolt
|
1
|
6
|
12 (1.2, 9)
|
|
|
Clutch center lock nut
|
1
|
18
|
80 (8.2, 59)
|
NOTE 1
|
|
Clutch spring bolt
|
|
6
|
12 (1.2, 9)
|
|
|
Gearshift return spring pin
|
1
|
8
|
22 (2.2, 16)
|
|
|
Gearshift pedal pinch bolt
|
1
|
6
|
12(1.2,9)
|
|
|
Kickstarter pedal bolt
|
1
|
8
|
38 (3.9, 28)
|
|
|
Primary drive gear bolt
|
1
|
12
|
108 (11.0, 80)
|
NOTE 1
|
|
Starter gear holder mounting bolt
|
3
|
7
|
18 (1.8, 13)
|
NOTE 1
|
|
|
ALTERNATOR
|
ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE N m (kgf-m, Ibf ft)
|
REMARKS
|
|
Flywheel nut
|
1
|
12
|
64 (6.5, 47)
|
NOTE 1
|
|
Ignition pulse generator mounting bolt
|
2
|
5
|
5.2 (0.5, 3.8)
|
NOTE 2
|
|
Stator mounting bolt
|
3
|
5
|
4.7 (0.5, 3.5)
|
NOTE 2
|
|
|
CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
|
ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE N m (kgf-m, Ibf ft)
|
REMARKS
|
|
Crankshaft bearing set plate torx
|
p
1
in
p
|
2
|
6
|
10(1.0,7)
|
NOTE 10
|
|
screw
|
(After '07)
|
2
|
6
|
20(2.0, 15)
|
NOTE 10
|
|
Countershaft bearing set plate screw
|
|
2
|
6
|
10(1.0,7)
|
NOTE 2
|
|
Gearshift drum bearing set plate bolt
|
|
2
|
6
|
10(1.0,7)
|
NOTE 2
|
|
Mainshaft bearing set plate bolt
|
|
2
|
6
|
10(1.0,7)
|
NOTE 2
|
|
Balancer shaft bearing set plate bolt
|
|
2
|
6
|
10(1.0,7)
|
NOTE 2
|
|
Balancer shaft nut
|
|
1
|
14
|
44 (4.5, 32)
|
NOTE 1
|
|
Cam chain tensioner bolt
|
|
1
|
6
|
12(1.2,9)
|
NOTE 2
|
|
|
IGNITION SYSTEM
|
ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE N-m (kgf-m, Ibf-ft)
|
REMARKS
|
|
Timing hole cap
|
1
|
14
|
10 (1.0, 7)
|
NOTE 7
|
|
|
ELECTRIC STARTER
|
ITEM
|
QTY
|
THREAD DIA. (mm)
|
TORQUE N-m (kgf-m, Ibf-ft)
|
REMARKS
|
|
Starter motor case bolt
|
2
|
4
|
3.4 (0.3, 2.5)
|
|
|
Insulator band:
|
12.0 ± 1.0 mm (0.47 ± 0.04 in)
|
'05 - '07: Cylinder head and carburetor side. After '07: Carburetor side.
Cylinder head side insulator band (After '07):
|
9.0 ±1.0 mm (0.35 + 0.04 in)
|
Cylinder stud bolt:
Water hose clamp:
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