Category Archives: ANUAL SERVICE M

LUBRICATION SEAL POINTS

ENGINE

LOCATION

MATERIAL

REMARKS

Decompressor shaft 20.9 mm and 14 mm O. D. areas (After ’07)

Decompressor plunger sliding area (After ’07) Camshaft journal and lobes Rocker arm bore and valve slipper surfaces Valve stem (valve guide sliding surface)

Valve stem end sliding surface

Valve lifter outer surface

Clutch outer guide inner surface

Clutch outer needle bearing rolling area

Clutch lifter lever cam area

Kickstarter pinion gear inner surface

Kickstarter spindle spline area and gear rolling area

Starter gear holder gear rolling surface

Connecting rod big end sliding area

Connecting rod small end inner surface

Transmission gear spline area, rolling area and sliding

surface

Shift fork gear guide area and guide pin area Shift fork sliding surface Shift fork shaft outer surface Each gear sliding surface

Use molybdenum oil solu­tion (mixture of the engine oil and molybdenum grease with the ratio 100g : 70 cc)

Mainshaft spline area and sliding surface Countershaft spline area and sliding surface

Use molybdenum oil solu­tion (mixture of the engine oil and molybdenum paste with the ratio 1:1)

Camshaft holder mounting bolt threads

Cylinder head nut threads and seating surface

Balancer shaft nut threads

Piston outer surface and piston pin hole

Piston pin outer surface

Piston rings

Cylinder bore

Decompressor cam mounting bolt threads (’05 — ’07) Decompressor lifter arm mounting nut threads and seating surface (’05 — ’07)

Decompressor adjuster lock nut threads (’05 — ’07)

Clutch lifter and lifter rod sliding area

Clutch lifter piece needle bearing

Clutch disc linings and plates

Clutch center lock nut threads and seating surface

Clutch outer sliding surfaces

Engine oil drain bolt threads and seating surface

Plug hole seal circumference

Primary drive gear bolt threads

One-way clutch outer surface

Starter clutch outer sliding surface

Starter driven gear sliding surface

Starter gear holder mounting bolt threads

Flywheel nut threads and seating surface

Transmission gear teeth

Transmission oil drain bolt threads and seating surface

Shift drum guide grooves

Gearshift spindle serration area

Oil pump rotors sliding area

Kickstarter spindle journal (15 mm O. D.)

Crankshaft oil seal outer surface Each bearing Each O-ring

Engine oil

LOCATION

MATERIAL

REMARKS

Crankshaft hole cap threads Timing hole cap threads Countershaft collar O-ring Armature shaft end Each oil seal lips Dust seal lips

Oil filter spring contact area Mechanical seal lips

Multi-purpose grease

Gearshift drum center pin bolt threads

Locking agent

Stator mounting bolt threads

Coating width: 4.5 ± 1.0 mm (0.18 ± 0.04 in) from tip

Ignition pulse generator mounting bolt threads

Coating width: 4.5 ± 1.0 mm (0.18 ± 0.04 in) from tip

Cam sprocket bolt threads

Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) from tip

Balancer shaft bearing set plate bolt threads

Mainshaft bearing set plate bolt threads Gearshift drum bearing set plate bolt threads

Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) from tip

Countershaft bearing set plate screw threads

Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) from tip

Cam chain tensioner bolt threads

Throttle shaft screw threads (’05, ’06) Throttle shaft torx screw threads (After ’06)

Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) from tip

Oil jet mounting bolt threads

Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) from tip

Crankcase tightening bolt threads APPLIED POSITION

Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) from tip

Crankshaft bearing set plate torx screw threads

Locking agent

Coating width: 6.5 ± 1.0 mm

(Pro Honda Hondalock 3 or equivalent high strength locking agent)

(0.26 ± 0.04 in) from tip

Alternator wire grommet sealing surface

Liquid sealant

FRAME

LOCATION

MATERIAL

REMARKS

Steering head bearing rolling area and dust seal lips

Urea based multi-purpose grease with extreme pres­sure (example: Kyodo Yushi EXCELITE EP2, Shell stamina EP2 or equiva­lent)

Apply 3 — 5 g for each bearing

Wheel bearing dust seal lips

Wheel bearing rolling area

Kickstarter arm joint

Swingarm pivot bolt sliding surface

Swingarm pivot needle bearing rolling area

Swingarm pivot thrust bearing rolling area

Swingarm pivot dust seal lips

Shock arm needle bearing rolling area

Shock arm dust seal lips

Shock linkage side collars

Shock linkage needle bearing sliding area

Rear shock absorber spherical bearing rolling area

Rear shock absorber dust seal lips

Brake pedal pivot bolt sliding surface

Gearshift change pedal sliding area of pin

Throttle cable end and sliding area

Clutch cable end adjuster inside surface

Clutch lever pivot bolt sliding surface

Sidestand pivot bolt sliding surface

Air cleaner element-to-air cleaner housing contacting

area (After ’07)

Multi-purpose grease

Apply 3.5 ±2 g

Brake caliper pin bolt sliding area Brake caliper bracket pin bolt sliding area Brake caliper dust seal lips

Brake caliper and bracket pin boots inside surface Brake lever pivot bolt sliding surface Brake lever adjuster tip

Rear master cylinder push rod rounded surface Rear master cylinder boot fitting area

Silicone grease

Drive chain slider screw threads

Fork protector mounting bolt threads

Front brake caliper mounting bolt threads

Front caliper pin bolt threads

Front caliper bracket pin bolt threads

Rear caliper bracket pin bolt threads

Steering damper mounting bolt threads (After ’07)

Locking agent

Brake caliper piston seal lips Brake caliper piston outer surface Master cylinder inner surface Master cylinder piston outer surface

DOT4 brake fluid

Handlebar grip rubber inner surface Air cleaner housing connecting surface

Honda Bond A or Pro Honda Handgrip Cement (U. S.A. only)

Fork cap O-rings Center bolt O-rings Fork bushing Fork oil seal Fork dust seal

Steering damper plug bolt O-ring (After ’07) Steering damper end cap O-ring (After ’07) Steering damper free piston O-ring (After ’07) Steering damper rod O-ring (After ’07)

Pro Honda HP Fork Oil 5W

Shock arm nut threads and flange surface Shock link nut threads and flange surface Throttle grip sliding area

Engine oil

LOCATION

MATERIAL

REMARKS

Front engine hanger-to-engine contacting area

Molybdenum disulfide paste (Dow Corning® 321 or equivalent)

Diffuser (’05 — ’07)

Sealant

Spark arrester mounting bolt threads (After ’07)

Molybdenum disulfide grease (TB1901 or equiva­lent)

FRAME

FRAME/BODY PANELS/EXHAUST SYSTEM

ITEM

QTY

THREAD DIA. (mm)

TORQUE N m (kgf-m, Ibf ft)

REMARKS

Seat mounting bolt

2

8

26 (2.7, 19)

Sub-frame upper mounting bolt

(’05-’07)

2

8

30 (3.1,22)

Sub-frame lower mounting bolt

(’05 — ’07)

2

10

49 (5.0, 36)

Sub-frame upper/lower mounting

bolt

(After ’07)

4

10

49 (5.0, 36)

Seat bracket screw

1

5

4 (0.4, 3.0)

Tank band hook screw

1

5

4 (0.4, 3.0)

Muffler joint band bolt

1

8

21 (2.1, 15)

Muffler mounting bolt

2

8

26 (2.7, 19)

Exhaust pipe joint nut

2

8

21 (2.1, 15)

Heat shield bolt

2

6

12(1.2, 9)

Exhaust pipe protector bolt

2

6

12(1.2,9)

Diffuser mounting torx screw

(’05-’07)

1

5

11 (1.1,8)

Radiator shroud upper mounting bolt

4

5

5 (0.5, 3.7)

Rear fender mounting bolt

4

6

13(1.3, 10)

MAINTENANCE

ITEM

QTY

THREAD DIA. (mm)

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

REMARKS

Sidestand pivot bolt

1

10

See page 4-34

NOTE 6

Sidestand pivot nut

1

10

39 (4.0, 29)

NOTE 4

Throttle cable adjuster lock

(throttle side)

1

7

4 (0.4, 3.0)

nut

(carburetor side)

1

6

4 (0.4, 3.0)

Spark arrester mounting bolt

(’05 — ’07)

4

6

12(1.2,9)

(After ’07)

4

6

6 (0.6, 4.4)

NOTE 9

FUEL SYSTEM

ITEM

QTY

THREAD

TORQUE

REMARKS

DIA. (mm)

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

Throttle bolt (carburetor side)

1

6

4 (0.4, 3.0)

PAIR control valve mounting nut

2

6

13(1.3, 10)

ENGINE REMOVAL/INSTALLATION

ITEM

QTY

THREAD DIA. (mm)

TORQUE N m (kgf-m, Ibf ft)

REMARKS

Engine hanger plate bolt

4

8

26 (2.7, 19)

Engine mounting nut

(front)

1

10

54 (5.5, 40)

(upper)

1

10

54 (5.5, 40)

(lower)

1

10

54 (5.5, 40)

FRONT WHEEL/SUSPENSION/STEERING

ITEM

QTY

THREAD

TORQUE

REMARKS

DIA. (mm)

N m (kgf-m, Ibf ft)

Front axle nut

1

16

88 (9.0, 65)

Front axle holder bolt

4

8

20 (2.0, 15)

Front spoke

36

BC3.5

3.68 (0.4, 2.7)

Front rim lock

1

8

12 (1.2, 9)

Front brake disc nut

6

6

16(1.6, 12)

NOTE 4

Steering stem nut

1

26

108 (11.0, 80)

Steering stem adjusting nut

1

30

See page 14-51

Fork top bridge pinch bolt

4

8

22 (2.2, 16)

Fork bottom bridge pinch bolt

4

8

20(2.0, 15)

Fork cap

2

39

30(3.1,22)

Fork center bolt

2

22

69 (7.0, 51)

Fork center bolt lock nut

2

12

22 (2.2, 16)

Pressure release screw

2

5

1.2 (0.1, 0.9)

Fork damper

2

50

34 (3.5, 25)

Fork protector mounting bolt

6

6

7 (0.7, 5.2)

NOTE 2

Front brake disc cover bolt

2

6

13 (1.3, 10)

Handlebar upper holder bolt

4

8

22 (2.2, 16)

Handlebar lower holder nut

2

10

44 (4.5, 32)

NOTE 4

Clutch lever pivot bolt

1

6

See page 14-52

NOTE 6

Clutch lever pivot nut

1

6

10(1.0,7)

NOTE 4

Engine stop button screw

1

4

1.5 (0.2, 1.1)

Engine starter switch housing screw

2

4

1.15(0.1,0.8)

Throttle bolt (throttle side)

1

6

4 (0.4, 3.0)

Tripmeter cable clamp screw

2

4

0.7 (0.1, 0.5)

Steering damper mounting bolt (After ’07)

2

7

20 (2.0, 15)

NOTE 2

REAR WHEEL/SUSPENSION

ITEM

QTY

THREAD DIA. (mm)

TORQUE N m (kgf-m, Ibf ft)

REMARKS

Rear axle nut

1

22

128(13.1,94)

NOTE 4

Rear spoke

32

4.5

3.7 (0.4, 2.7)

Rear rim lock

1

8

12 (1.2, 9)

Rear brake disc nut

6

6

16(1.6, 12)

NOTE 4

Driven sprocket nut

6

8

32 (3.3, 24)

NOTE 4

Rear wheel bearing retainer

1

50

44 (4.5, 32)

Swingarm pivot nut

1

14

88 (9.0, 65)

NOTE 4

Shock arm nut

(swingarm side)

1

12

53 (5.4, 39)

NOTE 1,4

(shock link side)

1

12

53 (5.4, 39)

NOTE 1,4

Shock link nut (frame side)

1

12

53 (5.4, 39)

NOTE 1,4

Shock absorber upper mounting nut

1

10

44 (4.5, 32)

NOTE 4

Shock absorber lower mounting nut

1

10

44 (4.5, 32)

NOTE 4

Shock absorber spring lock nut

1

60

44 (4.5, 32)

Drive chain slider screw

3

5

4.2 (0.4, 3.1)

NOTE 2

Drive chain roller bolt

1

8

12(1.2, 9)

Drive chain roller nut

1

6

12 (1.2, 9)

NOTE 4

Drive chain guide mounting bolt/nut

2

6

12 (1.2, 9)

NOTE 4

Drive chain adjuster lock nut

2

8

27 (2.8, 20)

NOTE 8

Shock absorber damper rod end nut

1

12

37 (3.8, 27)

NOTE 3

Shock absorber compression damping adjuster

1

27

29 (3.0, 21)

NOTE 3

Left step bracket mounting

(upper)

1

12

55 (5.6, 41)

bolt

(lower)

1

8

30 (3.1, 22)

HYDRAULIC BRAKE

ITEM

QTY

THREAD DIA. (mm)

TORQUE N m (kgf-m, Ibf ft)

REMARKS

Brake hose oil bolt

4

10

34 (3.5, 25)

Brake lever adjuster lock nut

1

5

5.9 (0.6, 4.4)

Brake lever pivot nut

1

6

5.9 (0.6, 4.4)

Brake lever pivot bolt

1

6

1.0 (0.1, 0.7)

Front brake hose guide bolt

2

6

5.2 (0.5, 3.8)

Rear brake hose guide screw

6

5

1.2 (0.1, 0.9)

Front master cylinder reservoir cover screw

2

4

1.0 (0.1, 0.7)

Front master cylinder holder bolt

2

6

9.9 (1.0, 7.3)

Front brake caliper mounting bolt

2

8

30 (3.1,22)

NOTE 2

Front/rear caliper bleed valve

2

8

5.4 (0.6, 4.0)

Rear master cylinder mounting bolt

2

6

13(1.3, 10)

Rear master cylinder reservoir cover bolt

2

4

1.0 (0.1, 0.7)

Front caliper pin bolt

1

8

22 (2.2,16)

NOTE 2

Rear caliper pin bolt

1

12

27 (2.8, 20)

Brake caliper pad pin

10

18 (1.8, 13)

Front brake caliper pad pin plug

1

10

2 (0.2, 1.5)

Front caliper bracket pin bolt

1

8

22 (2.2,16)

NOTE 2

Rear caliper bracket pin bolt

1

8

12(1.2, 9)

NOTE 2

Brake pedal pivot bolt

1

10

36 (3.7, 27)

NOTE 7

Brake pedal adjuster lock nut

1

6

5.9 (0.6, 4.4)

LIGHTS/METER/SWITCHES

ITEM

QTY

THREAD DIA. (mm)

TORQUE N m (kgf-m, Ibf ft)

REMARKS

Headlight mounting screw

2

5

0.7 (0.1, 0.5)

Tail light mounting screw

2

5

4.2 (0.4, 3.1)

Tail light wire clamp screw

2

4

0.7 (0.1, 0.5)

OTHERS

ITEM

QTY

THREAD DIA. (mm)

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

REMARKS

Right step bracket mounting

(upper)

1

12

55(5.6,41)

bolt

(lower)

1

8

30 (3.1,22)

LIGHTS/METER/SWITCHES SPECIFICATIONS

ITEM

SPECIFICATIONS

Headlight

12 V-35 W

Tail light

LED

Fuse

15 A

STANDARD TORQUE VALUES

FASTENER TYPE

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

FASTENER TYPE

TORQUE N m (kgf-m, Ibf ft)

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

5.2 (0.5, 3.8) 10(1.0, 7) 22 (2.2, 16) 34 (3.5, 25) 54 (5.5, 40)

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

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

MAINTENANCE

ITEM

QTY

THREAD DIA. (mm)

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

REMARKS

Engine oil drain bolt

1

8

16(1.6, 12)

NOTE 1

Transmission oil drain bolt

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

22 (2.2, 16)

LUBRICATION SYSTEM

ITEM

QTY

THREAD DIA. (mm)

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

REMARKS

Oil jet mounting bolt

1

6

10(1.0,7)

NOTE 2

FUEL SYSTEM

ITEM

Q’TY

THREAD DIA. (mm)

TORQUE N m (kgf-m, Ibfft)

REMARKS

Throttle drum cover bolt

1

5

3.4 (0.3, 2.5)

Needle jet

1

7

1.8 (0.2, 1.3)

Main jet

1

5

1.5 (0.2, 1.1)

Slow jet

1

10

1.5 (0.2, 1.1)

Slow air jet

(’05-’07)

1

5

0.9 (0.1, 0.7)

Starter jet

1

5

1.5 (0.2, 1.1)

Acc. pump bypass

1

4

0.3 (0.03, 0.2)

Carburetor top cover bolt

4

2.1 (0.2, 1.5)

Throttle shaft screw

(’05, ’06)

1

4

2.1 (0.2, 1.5)

NOTE 2

Throttle shaft torx screw

(After ’06)

1

4

2.1 (0.2, 1.5)

NOTE 2

Float chamber screw

4

2.1 (0.2, 1.5)

Accelerator pump cover screw

4

2.1 (0.2, 1.5)

Carburetor drain plug

1

18

4.9 (0.5, 3.6)

Carburetor drain screw

(After ’05)

1

6

1.5 (0.2, 1.1)

Choke valve lock nut

1

12

2.1 (0.2, 1.5)

Hot start valve lock nut

1

12

2.1 (0.2, 1.5)

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

(After ’06)

1

5

3.4 (0.3, 2.5)

COOLING SYSTEM

ITEM

QTY

THREAD DIA. (mm)

TORQUE Nm {kgf-m, Ibf ft)

REMARKS

Water pump impeller

1

7

12(1.2, 9)

ENGINE REMOVAL/INSTALLATION

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)

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

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

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)

LIGHTS/METER/SWITCHES SPECIFICATIONS

’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)

LIGHTS/METER/SWITCHES SPECIFICATIONS

LIGHTS/METER/SWITCHES SPECIFICATIONS

Cylinder stud bolt:

LIGHTS/METER/SWITCHES SPECIFICATIONS

I

Water hose clamp:

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Cold tire pressure

98 к Pa (1.0 kgf/cm!, 14 psi)

Axle runout

0.20 (0.008)

Wheel rim runout

Radial

2.0 (0.08)

Axial

2.0 (0.08)

Wheel hub-to-rim distance

See page 14-10

Fork

Spring free length

500 (19.7)

493 (19.4)

Slider runout

0.20 (0.008)

Recommended fork oil

Pro Honda HP Fork Oil 5W or equivalent

Oil level

42-47(1.65-1.85)

Fluid capacity (’05 — ’07)

Outer tube

332 cm3 (11.2 US оz, 11.7 Imp oz)

Fork damper

192 cm3 (6.5 US oz, 6.8 Imp oz)

Fluid capacity (After ’07)

Outer tube

324 cm3 (11.0 US oz, 11.4 Imp oz)

Fork damper

192 cm3 (6.5 US oz, 6.8 Imp oz)

Compression damping adjuster

’05 — ’07

14 clicks out from full in

standard position

After ’07

11 clicks out from full in

Rebound damping adjuster standard position

’05 — ’07

7 clicks out from full in

After ’07

6 clicks out from full in

Steering damper (After ’07)

Recommended damper oil

Pro Honda HP Fork Oil 5W or equivalent

Free piston depth at 20°C (68CF)

27.3-27.9(1.07-1.10)

Damping force adjuster standard position

9 clicks out from full in

REAR WHEEL/SUSPENSION SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Cold tire pressure

98 kPa (1.0 kgf/cm*, 14 psi)

Axle runout

0.20 (0.008)

Wheel rim runout

Radial

2.0 (0.08)

Axial

2.0 (0.08)

Wheel hub-to-rim distance

See page 15-11

Drive chain slack

25-35(1.0-1.4)

60 (2.4)

Drive chain width

13.4(0.53)

Drive chain size/link

DID

520MXV/114

Drive chain slider thickness

5.0 (0.20)

Drive chain roller O. D.

Upper

39 (1.5)

Lower

35 (1.4)

Shock

Damper gas pressure

980 kPa (10.0 kg/cm*, 142 psi)

absorber

Damper compressed gas

Nitrogen gas

Recommended shock oil

Pro Honda HP Fork Oil 5W or equivalent

Damper rod compressed force at 12 mm compressed

20.0 — 24.0 kgf (44.1 — 52.9 Ibf)

Standard oil capacity

395 cm3 (13.4 US oz, 13.9 Imp oz)

Spring installed length

’05 — ’07

258.5(10.18)

(standard)

After ’07

258.0 (10.16)

High speed side compression

’05 — ’07

3/4 -1-1/4 turns out from full in

damping adjuster standard position

After ’07

7/12 — 1-1/12 turns out from full in

Low speed side compression damping adjuster standard position

10 clicks out from full in

Rebound damping adjuster standard

Г-v

p

I

LD

О

11 — 14 clicks out from full in

_

position

After ’07

10 — 13 clicks out from full in

HYDRAULIC BRAKE SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Front

Brake fluid

DOT 4

Brake disc thickness

3.0 (0.12)

2.5(0.10)

Brake disc warpage

0.15(0.006)

Master cylinder I. D.

11.000(0.4331)

11.050 (0.4350)

Master piston O. D.

10.971 (0.4319)

10.840 (0.4268)

Caliper cylinder I. D.

27.025 (1.0640)

27.060 (1.0654)

Caliper piston O. D.

26.968(1.0617)

26.853 (1.0572)

Rear

Brake fluid

DOT 4

Brake disc thickness

4.0 (0.16)

3.5(0.14)

Brake disc warpage

0.15(0.006)

Master cylinder I. D.

9.547 (0.3759)

9.575 (0.3770)

Master piston O. D.

9.491 (0.3737)

9.465 (0.3726)

Caliper cylinder I. D.

22.650 (0.8917)

22.712 (0.8942)

Caliper piston O. D.

22.620 (0.8905)

22.573 (0.8887)

Brake pedal push rod standard length

79.6 mm (3.13 in)

BATTERY/CHARGING SYSTEM SPECIFICATIONS

ITEM

SPECIFICATIONS

Battery

Capacity

12 V-6 Ah

Current leakage

0.1 mA max.

Voltage

(20°C/68°F)

Fully charged

13.0-13.2 V

Needs

charging

Below 12.4 V

Charging cur­rent

Normal

0.6 A/5 — 10 h

Quick

3.0 A/1.Oh

Alternator

Capacity

78 W/5,000 rpm

IGNITION SYSTEM SPECIFICATIONS

ITEM

SPECIFICATION

Spark plug

Standard

(NGK)

IFR8H11

(DENSO)

VK24PR211

Optional

(NGK)

IFR9H11

(DENSO)

VK27PRZ11

Spark plug gap

1.0 — 1.1 mm (0.039 — 0.043 in)

Ignition coil resistance (at 20°C/68°F)

Primary

0.1 -0.3 n

Secondary with plug cap

9-16Ш

Secondary without plug cap

4-8 Ш

Ignition coil peak voltage

100 V minimum

Ignition pulse generator resistance (at 20°C/68°F)

180 — 280 О

Ignition pulse generator peak voltage

0.7 V minimum

Alternator exciter coil resistance (at 20°C/68°F)

9 — 28 £1

Ignition timing ("F" mark)

8° BTDC/1,800 rpm

Throttle position sensor (Blue — Black) resistance (at 20°C/68°F)

4-6Ш

ELECTRIC STARTER SPECIFICATION

ITEM

STANDARD

SERVICE LIMIT

Starter motor brush length

10.25 (0.404)

6.75 (0.266)