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)

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