Torque Values

FASTENER TYPE

TORQUE Nmi (kgf.m, Ibf.ft)

FASTENER TYPE

TORQUE N-m (kgf.m, Ibf.ft)

5 mm hex bolt and nut

6 mm hex bolt ond nut 8 mm hex bolt and nut 10 mm hex bolt and nut 12 mm hex bolt and nut

5 (0.5, 3.6) 10 (1.0, 7) 7? (7.7, 16) 34 (3.5, 25) 54 (5.5, 40)

5 mm screw

6 mm screw

6 mm flange bolt (8 mm head, small flange)

6 mm flange bolt (8 mm head, large flange)

5 mm flange bolt (10 mm head) and nut 8 mm flange holt and nut 10 mm flange bolt ond nut

12 (1.2. 9) 26 (2.7, 20) 39 (4.0, 29)

• Torque specifications listed below are for specific fasteners.

• Other fasteners should he tightened tn standard torque values listed above.

NOTES: 1. Apply sealant to the threads.

2 Apply a locking agent to the threads

4. Apply oil to the threads and flange surface.

6. ALOC bolt/screw: replace with a new one.

7. Apply grease to the threads.

8. Apply molybdenum disulfide oil to the threads and seating surface.

CIUVJIIMC

ITEM

Q'TY

THREAD

TORQUE

REMARKS

DIA. (mm)

N*m (kgf-m, lbf-ft)

MAINTENANCE:

Spark plug

4

10

12 (1.2, 9)

Timing hole cap

1

45

18 (1.8, 13)

NOTE 7

Engine oil filter cartridge

1

20

2G (2.7, 20)

NOTE 4

Engine oil drain bolt

1

12

29 (3.0, 22)

LUBRICATION SYSTEM:

Oil main gallery sealing holt

2

20

29 (3.0, 22)

NOTE 2

Oil pump cover bolt

1

6

8 (0.8, 5.8)

NOTE 9

Oil cooler bolt (filter boss)

1

20

64 (6.5. 47)

NOTE 4

FUEL SYSTEM (Programmed Fuel Injection):

ECT (Engine Coolant Temperature)/thermo sensor

1

17

23 (2.3, 17)

Throttle body insulator band screw

8

5

See page 1-14

Throttle cable bracket mounting bolt

2

5

3 (0.35, 2.5)

Starter valve lock nut

¿

10

2 (0.18, 1.3)

Starter valve synchronization plate screw

4

3

1 (0.09, 0.7)

Fast idle wax unit link plale screw

1

3

1 (0.09, 0.7)

Fast idle wax unit mounting screw

2

6

5 (0.5, 3.6)

Pressure regulator mounting bolt

2

6

10 (1.0, 7)

Vacuum joint for synchronization

2

5

3 (0.3. 2.2)

COOLING SYSTEM:

Water pump cover flongc bolt

2

6

12 (1.2, 9)

NOTE 9

Thermostat cover flange bolt

2

6

12 (1.2, 9)

NOTE 9

ENGINE MOUNTING:

Drive sprocket special bolt

1

10

54 (5.5, 4.0)

r ENGINE (Cont'd)

ITEM

QTY

THREAD DIA. (mm)

TORQUE N-m (kgf-m, lbf-ft)

REMARKS

CYLINDER HEAD/VALVES:

Cylinder head mounting bolt/washer

10

9

47 (4.8, 35)

NOTE 8

Camshaft holder flange bolt

20

6

12 (1.2, 9)

NOTE 4

Cylinder head sealing bull

1

14

1R (1.8, 13)

NOTE 2

Cylinder head cover holt

3

6

10(1.0, 7)

Breather plate flange bolt

3

6

12 (1.2, 9)

NOTE 2, 9

PAIR reed valve cover SH bolt

4

6

12 (1.2, 9)

NOTE 9

Cam sprocket flange dowel bolt

4

7

20 (2.0. 14)

NOTE 2

Cam pulse generator rotor flange dowel bolt

2

6

12 (1.2, 9)

NOTE 2

Cam chain lifter mounting socket bolt

2

6

10 (1.0, 7)

Cam chain tensioner pivot socket bolt

1

b

10(1.0, 7)

NOTE 2

Cam chain guide bolt/washer

1

6

12 (1.2, 9)

Cylinder head stud bolt (exhaust pipe stud bolt)

8

6

See page 1-14

CLUTCH/GEARSHIFT LINKAGE:

Clutch center lock nut

1

22

127 (13.0, 94)

NOTE 3, 4

Clutch spring bolt/washer

5

6

12 (1.2, 9)

Oil pump driven sprocket bolt/washer

1

6

lb (1.5, 11)

NOTE 2

Shift drum center socket bolt

1

8

23 (2.3, 17)

NOTE 2

Shift drum stopper arm pivot bolt

1

6

12 (1.2, 9)

Gearshift spindle return spring pin

1

8

22 (2.2, 16)

Ignition pulse generator wire guide holt/washer

1

6

12 (1.2, 9)

ALTERNATOR/STARTER CLUTCH:

Alternator stator socket bolt

4

6

1? (1.2, 9)

Starter clutch outer socket bolt

6

8

16 (1.6, 12)

NOTE 2

Flywheel flange bolt

1

10

103(10.5, 76)

NOTE 4

Starter wire clamp flange bolt

1

6

12 (1.2, 9)

NOTE 9

CRANKCASE/TRANSMISSION:

Mainshaft bearing set plate bolt

3

6

12(1.2, 9)

NOTE 2

Gearshift drum bearing/fork shaft set bolt/'washer

2

6

12 (1.2, 9)

NOTE 2

Crankcasc bolt (main journal)

10

8

25 (2.6, 19)

NOTE 8

Crankcase bolt

1

10

39 (4.0, 29)

Crankcase bolt

6

7

18 (1.8. 13)

Crankcase bolt (upper side)

5

8

25 (2.5, 18)

CRANKSHAFT/PISTON/CYLINDER:

Connecting rod bearing cap nut

8

7

25 (2.6, 19)

NOTE 4

IGNITION SYSTEM:

Ignition pulse generator rotor special bolt

1

10

59 (6.0, 43)

ELECTRIC STARTER:

Starter motor terminal nut

1

6

12 (1.2, 9)

LIGHTS/METERS/SWITCHES:

Oil pressure switch

1

PT 1/8

12 (1.2, 9)

NOTE 1

Oil pressure switch wire terminal bolt/washer

1

4

2 (0.2, 1.4)

Neutral switch

1

10

12 (1.2, 9)

Insulator clamp (throttle body side):

Insulator clamp (cylinder head side):

4 i 1 mm (0.2 ± 0.04 in)

Exhaust pipe stud bolt:

FRAME

ITEM

FRAME BODY PANELS/EXHAUST SYSTEM:

Upper cowl to lower cowl screw Inner half cowl-to-lower cowl screw Windscreen setting screw Seat rail upper mounting flange bolt/nut Scat rail lower mounting flange bolt/nut Exhaust pipe joint flange nut Muffler band flange bolt Passenger footpeg bracket flange bolt FUEL SYSTEM (Programmed Fuel Injection): Fuel filler cap bolt Service check bolt Fuel hose banjo boll (fuel tank side) Fuel hose sealing nut (throttle body side) Fuel pump mounting nut

Injection Fuel Tank

THREAD

THREAD

Os sensor (California type only) COOLING SYSTEM: Cooling fan mounting nut Fan motor mounting nut ENGINE MOUNTING: Front engine hanger bolt Center engine hanger bolt Center engine hanger adjusting bolt Center engine hanger lock nut Rear engine hanger nut Rear engine hanger adjusting bolt Rear engine hanger lock nut (right side) Shock link bracket nut FRONT WHEEL/SUSPENSION/STEERING: Handlebar weight mounting screw Front brake disc bolt Front axle bolt Front axle holder flange bolt Front brake hose clamp flange bolt (left front) Front brake hose 3-way joint flange bolt (right front) Fork socket bolt Fork bolt

Fork top bridge pinch socket bolt Fork bottom bridge pinch flange bolt Steering bearing adjusting nut Steering bearing adjusting nut lock nut Steering stem nut

Front brake hose clamp bolt (steering stem)

1 (0.05, 0.4) 49 (5.0, 36) 49 (5.0, 36) 12 (1.2, 9) 23 (2.3, 17) 26 (2.7, 20)

2 (0.18, 1.3) 15 (1.5, 11) 22 (2.2, 16) 22 (2.2, 16) 1? (1.2, 9)

REMARKS

39 (4.0, 29) 39 (4.0, 29) 3 (0.3, 2.2) 54 (5.5, 40) 39 (4.0, 29) 3 (0.3, 2.2) 54 (5.5, 40) 39 (4.0, 29)

10 (1.0, 7) 20 (2.0, 14) 59 (6.0, 43) 22 (2.2, 16) 12 (1.2, 9) 12 (1.2, 9) 34 (3.5, 25) 23 (2.3, 17) 23 (2.3, 17) 39 (4.0, 29) 25 (2.5, 18)

NOTE 2

See page 7-10

NOTE 6 NOTE 6

NOTE 2

See page 13-29

- rnMivic. luuiii u/---

ITEM

QTY

THREAD

TORQUE

REMARKS

DIA. (mm)

N-m (kgf-m, lbf-ft)

REAR WHEEL/SUSPENSION:

Rear brake disc bolt

4

8

42 (4.3, 31)

NOTE 6

Final driven sprocket nut

6

10

64 (6.5, 47)

NOTE 5

Hear axle nut

1

18

93 (9.5, 69)

NOTE 5

Rear shock absorber mounting nut

2

10

44 (4.5, 33)

NOTE 5

Shuck link plate-to-swingarm nut

1

10

44 (4.b, 33)

NOTE 5

Shock link-to-shock link plate nut

1

10

44 (4.5, 33)

NOTE 5

Shock link-to-bracket nut

1

10

44 (4.5, 33)

NOTE 5

Drive chain slider flange bolt

2

6

9 (0.9, 6.5)

NOTE 6

Swingarm pivot adjusting bolt

2

30

7(0.7,5.1) ,

See page 14 22

Swingarm pivot adjusting bolt lock nut

2

30

64 (6.5, 47) —I

Swingarm pivot nut

1

18

93 (9.5, 69) —

HYDRAULIC BRAKE:

Front master cylinder reservoir cap screw

2

4

2 (0.2, 1.1)

Front brake lever pivot bolt

1

6

1 (0.1, 0.7)

Front brake lever pivot nut

1

6

6 (0.6, 4.3)

hront hrake light switch screw

1

4

1 (0.1, 0.7)

Front master cylinder mounting bolt

2

6

12 (1.2, 9)

Front brake caliper assembly torx bolt

8

8

23 (2.3, 17)

NOTE 2

Tront brake caliper mounting flange bolt

4

8

30 (3.1, 22)

NOTE 6

Rear master cylinder push rod joint nut

1

8

18 (1.8, 13)

Rear master cylinder mounting bolt

2

6

9 (0.9, 6.5)

Rear brake reservoir mounting bolt/nut

1

6

12 (1.2, 9)

Rear brake caliper bolt

1

3

23 (2.3, 17}

Rear brake caliper pin bolt

1

12

27 (2.8, 20)

Pad pin

5

10

18 (1.8, 13)

Pad pin plug

1

10

3 (0.3, 2.2)

Brake hose oil bolt

5

10

34 (3.5, 25)

Brake caliper bleeder valve

3

8

6 (0.6, 4.3)

LIGHTS/METERS/SWITCHES:

Side stand switch bolt

1

6

10 (1.0,7)

NOTE 6

Ignition switch mounting bolt

2

8

25 (2.5, 18)

Tan motor switch

1

16

18 (1.8, 13)

NOTE 1

OTHERS:

Side stand pivot bolt

1

10

10 (1.0, 7)

Side stand pivot lock nut

1

10

29 (3.0, 22)

Side stand bracket flange bolt

2

10

44 (4.5. 33)

NOTE 6

Driver footpeg brackct sockct bolt

4

8

26 (2.7, 20)

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