2-30

PERIODIC MAINTENANCE

CHASSIS BOLTS AND NUTS

Tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-31 for the locations of the following nuts and bolts on the motorcycle.) It e m S teer ing stem head nut Steer ing stem lock-nut Front fork upper clamp bolt Front fork lower clamp bolt Front fork cap bolt Front axle bolt Front axle pinch bolt H an dl eba r c l am p b ol t Front brake master cylinder mounting bolt Front brake caliper mounting bolt Front brake caliper housing bolt B rake hose union bolt (Front & Rear) Air bleeder valve (Front brake caliper & Rear brake caliper) A ir bleeder valve (Master cylinder) B rake disc bolt (Front) B rake disc bolt (Rear) Rear brake caliper mounting bolt Rear brake master cylinder mounting bolt Rear brake master cylinder rod lock-nut Front footrest bracket mounting bolt S wingar m pivot nut S wingar m pivot lock-nut Rear suspension bracket nut Rear shock absorber mounting bolt/nut (Upper & Lower) Cushion rod nut Cushion lever mounting nut Rear axle nut Rear sprocket nut Steering damper bolt/nut Rear brake caliper pin bolt Nm 90 80 23 23 23 100 23 23 10 39 22 23 7.5 6.0 23 35 17 10 18 23 100 90 115 50 78 98 100 93 23 32 kgf-m 9 .0 8 .0 2 .3 2 .3 2 .3 1 0.0 2 .3 2 .3 1.0 3 .9 2 .2 2 .3 0.75 0 .6 2 .3 3 .5 1 .7 1.0 1 .8 2 .3 1 0.0 9 .0 1 1.5 5.0 7.8 9.8 10.0 9.3 2.3 3.2 Ib-ft 65 .0 5 8 .0 1 6 .5 16 .5 16 .5 72 .5 16 .5 1 6 .5 7.0 2 8 .0 1 6 .0 16 .5 5.5 4 .5 16 .5 2 5 .5 12 .5 7.0 1 3 .0 1 6 .5 72 .5 6 5 .0 83 .0 36.0 56.5 71.0 72.5 67.5 16.5 23.0

SERVICING INFORMATION

10-37

TIGHTENING TORQUE
ENGINE
ITEM Exhaust pipe bolt Muffler connecting bolt Muffler mounting bolt Speed sensor rotor bolt Speed sensor bolt Engine sprocket nut Engine mounting bolt (Cylinder) Engine mounting nut (Crankcase) Engine mounting thrust adjuster Engine mounting thrust adjuster lock-nut Engine mounting pinch bolt Cylinder head cover bolt Spark plug Cam chain guide No.1 bolt Camshaft journal holder bolt Cam chain tension adjuster cap bolt Cam chain tension adjuster mounting bolt Cam chain tensioner bolt Cam chain drive sprocket bolt Cylinder head bolt Step 1/step 3 (M: 10) Final step (M: 6) Water jacket plug Clutch cover bolt Clutch sleeve hub nut Clutch spring set bolt Clutch release adjuster cap Clutch lifter adjuster lock-nut Starter idle gear cover bolt Valve timing inspection plug Starter clutch bolt Generator cover bolt Generator rotor bolt Generator stator set bolt Gearshift cam stopper bolt Gearshift cam stopper plate bolt Oil pressure switch Oil filter Nm 23 23 23 25 4.5 115 55 75 23 45 23 14 11 23 10 23 10 23 54 31 10 9.5 10 95 10 11 23 10 11 10 10 120 10 10 13 14 20 kgf-m 2.3 2.3 2.3 2.5 0.45 11.5 5.5 7.5 2.3 4.5 2.3 1.4 1.1 2.3 1.0 2.3 1.0 2.3 5.4 3.1 60 1.0 0.95 1.0 9.5 1.0 1.1 2.3 1.0 1.1 1.0 1.0 12.0 1.0 1.0 1.3 1.4 2.0 lb-ft 16.5 16.5 16.5 18.0 3.0 83.0 39.8 54.0 16.5 32.5 16.5 10.0 8.0 16.5 7.0 16.5 7.0 16.5 39.0 22.5 7.0 6.9 7.0 68.5 7.0 8.0 16.5 7.0 8.0 7.0 7.0 87.0 7.0 7.0 9.5 10.0 14.5

10-38

SERVICING INFORMATION

ITEM Crankcase bolt (Initial) (M: 6) (Final) (Initial) (M: 8) (Final) (Initial) (M: 8) (Final) (M: 9) (M: 6) (M: 10) (M: 12) (M: 16)

Crankcase bolt (Inner hexagon) Crankshaft journal bolt Oil gallery plug

Oil drain plug Piston cooling oil jet bolt Oil pump mounting bolt Conrod bearing cap bolt Bearing retainer screw Breather cover bolt Oil pan bolt Oil cooler mounting bolt Driveshaft bearing case bolt (LH and RH) Starter motor mounting bolt

(Initial) (Final)

Nm 6 11 15 26 15 22 22 10 18 15 35 23 10 10 15 10 10 10 10 12 6

kgf-m 0.6 1.1 1.5 2.6 1.5 2.2 2.2 1.0 1.8 1.5 3.5 2.3 1.0 1.0 1.5 90 (1/4 turn) 1.0 1.0 1.0 1.0 1.2 0.6

lb-ft 4.5 8.0 11.0 19.0 11.0 16.0 16.0 7.0 13.0 11.0 25.5 16.5 7.0 7.0 11.0 7.0 7.0 7.0 7.0 8.7 4.5

FI SYSTEM AND INTAKE AIR SYSTEM

ITEM CKP sensor mounting bolt HO2 sensor (For E-02, 19) Fuel deliver y pipe mounting screw F ue l pum p m oun ti ng b ol t TPS and STPS mounting screw EXCVA mounting bolt E XCVA pulley mounting bolt Nm 8 48 5 10 3. 5 5 5 kgf-m 0 .8 4 .8 0 .5 1 .0 0. 35 0 .5 0 .5 lb-ft 6.0 3 4.5 3.5 7.0 2.5 3.5 3.5

COOLING SYSTEM
ITEM Impeller securing bolt Water pump cover screw Water pump mounting bolt Cooling fan mounting bolt ECT sensor Thermostat connector bolt Thermostat cover bolt Water inlet connector bolt Nm 8 5 10 8 18 10 10 10 kgf-m 0 .8 0 .5 1 .0 0 .8 1 .8 1 .0 1 .0 1 .0 lb-ft 6.0 3 .5 7.0 6.0 1 3 .0 7.0 7 .0 7.0

SERVICING INFORMATION

10-39

CHASSIS
ITEM Steering stem head nut Steering stem lock-nut Steering damper bolt and nut Front fork upper clamp bolt Front fork lower clamp bolt Front fork cap bolt Front fork inner rod lock-nut Front fork damper rod bolt Front axle bolt Front axle pinch bolt Han dl eba r c l am p b ol t Clutch lever pivot bolt Clutch lever lock-nut Brake lever pivot bolt Brake lever lock-nut Front brake master cylinder mounting bolt Front brake caliper mounting bolt Front brake caliper housing bolt Front brake pad mounting pin Brake hose union bolt Clutch lever holder mounting bolt Air bleeder valve (Front and rear brake caliper) Air breeder valve (Master cylinder) Brake disc bolt (Front) Brake disc bolt (Rear) Rear brake caliper mounting bolt Rear brake caliper pin bolt Rear brake pad mounting pin Rear brake master cylinder mounting bolt Rear brake master cylinder rod lock-nut Front footrest bracket mounting bolt Swingar m pivot shaft Swingar m p ivot nut Swingar m pivot lock-nut Cushion lever mounting nut Cushion rod mounting nut Rear shock absorber mounting bolt and nut (Upper and Lower) Rear axle nut Rear sprocket nut Side-stand mounting bracket bolt Rear shock absorber bracket nut Cowling brace bolt and nut Nm 90 80 23 23 23 35 20 35 10 0 23 23 1. 0 6. 0 1. 0 6. 0 10 39 22 15 23 10 7.5 6. 0 23 35 17 32 15 10 18 23 15 10 0 90 98 78 50 10 0 93 50 11 5 23 kgf-m 9 .0 8 .0 2 .3 2 .3 2 .3 3 .5 2 .0 3 .5 1 0.0 2 .3 2 .3 0 .1 0 .6 0 .1 0 .6 1 .0 3 .9 2 .2 1 .5 2 .3 1 .0 0.75 0 .6 2 .3 3 .5 1 .7 3 .2 1 .5 1 .0 1 .8 2 .3 1 .5 1 0.0 9 .0 9 .8 7 .8 5.0 1 0.0 9 .3 5 .0 1 1.5 2 .3 lb-ft 65.0 5 8 .0 16.5 16.5 16.5 25.5 1 4 .5 25.5 72.5 1 6 .5 16.5 0 .7 4.5 0.7 4.5 7.0 28.0 16.0 11.0 16.5 7.0 5.5 4.3 16.5 25.5 1 2 .5 2 3 .0 11.0 7.0 13.0 16.5 11 .0 72.5 6 5 .0 71.0 56.5 36.0 72.5 6 7 .5 3 6 .0 83.0 16.5

10-40

SERVICING INFORMATION

ITEM S eat rail bolt Rear view mirror nut

Nm 50 10

kgf-m 5 .0 1 .0

lb-ft 3 6.0 7.0

TIGHTENING TORQUE CHART

Bolt Diameter (mm) 4 5 6 8 10 12 14 16 18

For other nuts and bolts not listed in the preceding page, refer to this chart: Conventional or 4 marked bolt Nm kgf-m lb-ft 1.5 0.15 1.0 3 0.3 2.0 5.5 0.55 4.0 13 1.3 9.5 29 2.9 21.0 45 4.5 32.5 65 6.5 47.0 105 10.5 76.0 160 16.0 115.5 Nm 2.3 4.5 10 23 50 85 135 210 240 7 marked bolt kgf-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21.0 24.0 lb-ft 1.5 3.0 7.0 16.5 36.0 61.5 97.5 152.0 173.5

Conventional bolt

4 marked bolt

7 marked bolt