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:

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