SERVICE INFORMATION
• Place the motorcycle on a level ground before starting any work.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored
can cause a fire or explosion.
• If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area.
• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
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ITEM |
SPECIFICATIONS |
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Throttle grip freeplay |
3-5 mm (1/8-3/16 in) |
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Hot start lever freeplay |
2-3 mm (1/16-1/8 in) |
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Spark plug |
NGK |
DENSO |
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Standard |
IFR8H11 |
VK24PRZ11 |
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Option |
IFR9H11 |
VK27PRZ11 |
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Spark plug gap |
1.0 - 1.1 mm (0.039 - 0.043 in) |
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Valve clearance |
IN |
0.16 ± 0.03 mm (0.006 ± 0.001 in) |
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EX |
0.28 ± 0.03 mm (0.011 ± 0.001 in) |
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Decompressor clearance ('05 - '07) |
EX valve clearance + 0.35 mm (0.014 in) |
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Engine oil capacity |
At draining |
0.67 liter (0.71 US qt, 0.59 Imp qt) |
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At oil filter change |
0.70 liter (0.74 US qt, 0.62 Imp qt) |
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At disassembly |
0.87 liter (0.92 US qt, 0.77 Imp qt) |
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Transmission oil capacity |
At draining |
0.65 liter (0.69 US qt, 0.57 Imp qt) |
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At disassembly |
0.75 liter (0.79 US qt, 0.66 Imp qt) |
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Recommended engine oil |
Pro Honda GN4 4-stroke oil (U. S.A. and Canada) or equivalent motor oil API service classification: SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W-30 |
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Recommended transmission oil |
Pro Honda GN4 4-stroke oil (U. S.A. and Canada) or equivalent motor oil API service classification: SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W-30 |
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Recommended antifreeze |
Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing silicate free corrosion inhibitors. |
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Engine idle speed |
1,700 ± 100 rpm |
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Drive chain size/link |
DID |
520MXV/114 |
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Drive chain slack |
25-35 mm (1.0-1.4 in) |
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Drive chain width |
13.4 mm (0.53 in) |
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Drive chain slider thickness |
5.0 mm (0.20 in) |
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Drive chain roller O. D. |
Upper |
39 mm (1.5 in) |
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Lower |
35 mm (1.4 in) |
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Clutch lever freeplay |
10-20 mm (3/8-13/16 in) |
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Tire size |
Front |
80/100-21 51M |
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Rear |
110/100-18 64M |
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Cold tire pressure |
Front |
98 к Pa (1.0 kgf/cmJ, 14 psi) |
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Rear |
98 kPa (1.0 kgf/cmJ, 14 psi) |
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Brake pedal push rod standard length |
79.6 mm (3.13 in) |
Engine oil drain bolt
Transmission oil drain bolt
Transmission oil check bolt Crankshaft hole cap
Spark plug
Throttle cable adjuster lock nut
(throttle side) (carburetor side)
Brake lever adjuster lock nut Rear axle nut Drive chain roller bolt Drive chain roller nut Drive sprocket bolt Driven sprocket nut
Front master cylinder reservoir cover screw Rear master cylinder reservoir cover bolt Exhaust pipe joint nut Muffler joint band bolt
Spark arrester mounting bolt ('05 - '07)
(After '07)
16 N-m (1.6 kgf-m, 12 Ibf ft)
16 N-m (1.6 kgf-m, 12 Ibf-ft)
10 N-m (1.0 kgf-m, 7 Ibf-ft)
15 N-m (1.5 kgf-m, 11 Ibf-ft)
22 N-m (2.2 kgf-m, 16 Ibf-ft)
4.0 N-m (0.4 kgf-m, 3.0 Ibf-ft)
4.0 N-m (0.4 kgf-m, 3.0 Ibf-ft)
5.9 N-m (0.6 kgf-m, 4.4 Ibf-ft) 128 N-m (13.1 kgf-m, 94 Ibf-ft) 12 N-m (1.2 kgf-m, 9 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
31 N-m (3.2 kgf-m, 23 Ibf-ft)
32 N-m (3.3 kgf-m, 24 Ibf-ft)
1.0 N-m (0.1 kgf-m, 0.7 Ibf-ft)
1.0 N-m (0.1 kgf-m, 0.7 Ibf-ft) 21 N-m (2.1 kgf-m, 15 Ibf-ft)
21 N-m (2.1 kgf-m, 15 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
6 N-m (0.6 kgf-m, 4.4 Ibf-ft)
Apply oil to the threads and seating surface Apply oil to the threads and seating surface
Apply grease to the threads
U-nut
U-nut
U-nut
Apply molybdenum disulfide grease (TB1901 or equivalent) to the threads
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3.68 N-m (0.4 kgf-m, 2.7 Ibf-ft) 3.7 N-m (0.4 kgf-m, 2.7 Ibf-ft) 12 N-m (1.2 kgf-m, 9 Ibf-ft) 1.2 N-m (0.1 kgf-m, 0.9 Ibf-ft) See page 4-34 39 N-m (4.0 kgf-m, 29 Ibf-ft) 5.9 N-m (0.6 kgf-m, 4.4 Ibf-ft) 27 N-m (2.8 kgf-m, 20 Ibf-ft) 10 N-m (1.0 kgf-m, 7 Ibf-ft) |
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U-nut Apply oil to the threads |
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Front spoke Rear spoke Front/rear rim lock Pressure release screw Sidestand pivot bolt Sidestand pivot nut Brake pedal adjuster lock nut Drive chain adjuster lock nut Decompressor adjuster lock nut ('05 - '07) |
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