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Insideofthebodycowling

Wiringharness

ClampClamp

Handlebarswitch(L·R)Ignitionswitch

Clampthewiringharnesstotheframe.

Wiringharness

-

Wiringharness

Tothefrontturnsignallight(R)

Wiringharness

Waterhose

Clamp

Facetheclampendtodownward.

Wiringharness

Waterhose

Clamp

Clamp

Handlebarswitch

(L·R)

e

Passtheside-standswitchleadwireoverthebattery

leadwire.

ClampClamp

Wiringharness

Battery~

Donotputthetipofclampintothebatterybox.

Clamp

Battery8

Handlebarswitch(L·R)

I

WiringharnessClampthew1nng

Fanmotorharnesstotheframe.

Clamp

Wirinharness

Wiringharness

Rearturn

Isignallight(L)

Clamp

,~u..'Wiringharness

IRegulator/Rectifier

/Clamp

\

Passthefuelpumpleadwirebetweentheenginecoolantbypasshoseandengine

Wiringharness

Clamp

OilpressureswitchWiringharness

Side-standswitch\BatteryplusleadwireStartermotorPassthebatteryplusleadResistorwirebetweentheECMand

starterrelay.

InstallTosensorsothat

itspawlshouldcomeoutsidetherubberpartsecurely

Clamp

StartermotorleadwirePassthroughthestartermotorleadwirebehindoftheseatlockcable.

Clamp

Wiringharness

Fanmotor-

Setlheiruectorcouplertotheoptimumpositionafterconnectingtheinjectorlead

wirecouplerPasstheneutralswitch

leadwirebehindthebypass

hoseandbreatherhose

InsertTosensoruptotherootofrearfendersecurely.

s:

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PAIR{AIRSUPPLY)SYSTEMHOSEROUTING

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PAIRvalvehose(50mm)

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FRAMECOVERSET-UP

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~23N·m

(2.3kgf·m,16.5lb-ft)

Frontseat

HEATSHIELDSET-UP

Leftundercowling

LeftundercowlingheatshieldNo.2

CenterundercowlingheatshieldNo.1

CenterundercowlingheatshieldNo.2

Rightundercowling--.:!~ym.~~

heatshieldNo.3

Centerundercowling

~50N·m

I(5.0kgf·m.36.2lb-ft)

~40N·m

(4.0kgf·m,28.9lb-ft)

GEARSHIFTPEDALSET-UP

-----.------------------=-~I

Footrest

//"\

52-62mm

(2.05-2.44in)

-

SPECIALTOOLS

09900-06104

Snapringpliers

09900-06107

Snapringpliers

09900-06108

Snapringpliers

09900-20101

09900-20102

Verniercalipers

09900-20203

09900-20205

0990Q-20602

09900-20605

Micrometer

Micrometer

09900-20508

Dialgauge

Dialcalipers

(50-75mm)

(0-25mm)

Cylindergaugeset

(1/1000mm,1mm)

(1/100mm,10-34mm)

09900-20607

09900-20803

Dialgauge

09900-20701

09900-20806

09900-20805

09900-21304

(1/100mm,10mm)

Magneticstand

Thicknessgauge

Tiredepthgauge

V-block(100mm)

09900-22301

0990Q-22401{10-18

mm)

09913-10750

09900-22302

0990Q-22403(18-35

mm)

09900-25008

09910-20115

Compressiongauge

Plastigauge

Smallboregauge

Multicircuittesterset

Conrodholder

adapter

09913-13121

09913-50121

09913-70210

09915-40610

09915-64510

Carburetorbalancerset

Oilsealremover

Bearinginstallerset

Oilfilterwrench

Compression

gauge

-

~~

09915-74520

09915-74540

09915-77330

09916-14510

Oilpressuregauge

Oilpressuregauge

Meter

09916-10911

Valvespring

hose

adaptor

(forhighpressure)

Valvelapperset

compressor

"->"-11",.-.._v-.

09916-14521

09916-20630

09916-20650

Valvespringcompressor

09916-21111

Valveseatcutterhead

Solidpilot

09916·34542

attachment

Valveseatcutterset

(N-126)

(N-100-4.0)

Reamerhandle

09916-33310

09916-49030

09916-53310

Valveguidereamer

Valveguidereamer

Valvequide

09916-43220

09916-84511

(4.0mm)

(9.3mm)

remover/installer

Attachment

Tweezers

~~

09920-53740

09922-22711

09917-47010

09920-34830

Clutchsleevehub

09921-20220

Drivechaincutting

Vacuumpumpgauge

Starterclutchholder

holder

Bearingremoverset

andjoiningtool

6~-

09924-84521

Bearinginstallerset

09916-14530

Valvespringcompres•

sorattachment

09925-18011

Steeringbearinginstaller

09930-11920

TorxbitJT40H

09930-11940

Bitholder

-

~

09940-14911

09930-11960

09930-34980

09930-44520

09930-82710

Steeringstemnut

Torxwrench

Rotorremover

Rotorholder

Modeselection

switchwrench

09940-14960

Steeringnutwrench

09940-14970

Swingarmpivotshaft

09940-14990

Enginemountingthrust

09940-30221

Frontforkassembling

09940-40211

Fuelpressuregauge

socket

locknutsocketwrench

adjustersocketwrench

tool

adaptor

~

~

ti!fil

09940-40220

09940-50120

09940-94922

Fuelpressuregauge

Frontforkinnerrod

09940-92720

Frontforkspringstop-

09940-94930

hoseattachment

holder

Springscale

perplate

Frontforkspacerholder

~~

.....

......

~

09941-34513

09943-74111

09944-60210

Steeringraceinstaller

Forkoillevelgauge

Wheelbearingremover

NOTE:

Whenorderthespecialtool,pleaseconfirmwhetheritisavailableornot.

TIGHTENINGTORQUE

ENGINE

ITEM

N·m

kaf·m

lb-ft

Exhaustoioebolt

23

2.3

16.5

Mufflermountinanut

23

2.3

16.5

Soeedsensorrotorbolt

20

2.0

14.4

Enainesprocketnut

115

11.5

83.2

Enginemountingboltandnut(M:12)

75

7.5

54.0

(M:10)

55

5.5

39.8

Enainemountinathrustadjuster

23

2.3

16.5

Enoinemountinathrustadjusterlocknut

45

4.5

32.5

Enginemountingpinchbolt

23

2.3

16.5

Cylinderheadcoverbolt

14

1.4

10.0

Sparkplug

11

1.1

8.0

Camchainguidebolt

10

1.0

7.0

Camshaftjournalholderbolt

10

1.0

7.0

Camchaintensionadjustercapbolt

23

2.3

16.5

Camchaintensionadjustermountingbolt

10

1.0

7.0

Cylinderheadsidebolt

14

1.4

IO.O

Camchaintensionerbolt

10

1.0

7.0

Cylinderheadbolt(M:10)

46

4.6

33.3

(M:6)

10

1.0

7.0

PAIRreedvalvecoverbolt

10

1.0

7.0

Waterjacketplug

9.5

0.95

6.9

Waterinletcoverbolt

10

1.0

7.0

Clutchcoverbolt

10

1.0

7.0

Clutchsleevehubnut

150

15.0

108

Clutchsprinosetbolt

10

1.0

7.0

Starterclutchcoverbolt

10

1.0

7.0

Starteridleaearcoverbolt

10

1.0

7.0

Valvetiminainspectionplua

11

1.1

8.0

Starterclutchbolt

55

5.5

40.0

Generatorcoverbolt

10

1.0

7.0

Generatorrotorbolt

120

12.0

88.5

Generatorstatorsetbolt

10

1.0

7.0

Gearshiftcamstopperbolt

10

1.0

7.0

Gearshiftcamstopperplatebolt

10

1.0

7.0

Oilpressureswitch

14

1.4

10.0

Crankcasebolt(M:6)

11

1.1

8.0

(M:8)

26

2.6

19.0

(M:9)

32

3.2

23.0

Oilgalleryplug(M:6)(M:10)

11

1.1

8.0

(M:16)

35

3.5

26.5

Oildrainplug

23

2.3

16.5

-

ITEMPistoncoolinaoilietbolt

N-m

10

kgf.m

1.0

lb-ft

7.0

Oiloumomountinabolt

10

1.0

7.0

Conrodbearingcapbolt

(Initial)

15

1.5

11.0

(Final)

90°

(Vaturn)

Bearinaretainerscrew

10

1.0

7.0

Breathercoverbolt

10

1.0

7.0

Oilstrainerbolt

Oilpanbolt

10

10

1.0

1.0

7.0

7.0

Oilcoolerbolt

10

1.0

7.0

FlSYSTEMANDINTAKEAIRSYSTEM

Camshaftpositionsensormounting

bolt

8

0.86.0

Intakeairtemperaturesensor

18

1.8

13.0

Fueldeliverypipemountingscrew

5

0.5

3.7

Fuelpumpmountingbolt

10

1.0

7.0

Throttlebodyconnectingbolt

5

0.5

3.5

STVAmotoryokemountinabolt

3.5

0.35

2.5

STVAmotorcovernut

2.0

0.2

1.5

ITEMN·mkgf·mlb-ft

COOLINGSYSTEM

ITEM

N·m

kaf·m

lb-ft

Impellersecurinabolt

8

0.8

6.0

Waterournocoverbolt

6

0.6

4.5

Waterpumpmountinqbolt

10

1.0

7.0

Coolinafanthermo-switch

17

1.7

12.5

Enainecoolanttemperature

sensor

18

1.8

13.0

Thermostatcasebolt

10

1.0

7.0

8·32SERVICINGINFORMATION

CHASSIS

ITEM

Steerinostemheadnut

N·m

90

kgf·m

9.0

lb-ft

65.0

Steerinastemlocknut

80

8.0

58.0

Steerinadamoerboltandnut

23

2.3

16.6

Frontforkupperclampbolt

23

2.3

16.5

Frontforklowerclampbolt

23

2.3

16.5

Frontforkcapbolt

35

3.5

25.5

Frontforkinnerrodlocknut

20

2.0

14.5

Frontforkdamperrodbolt

35

3.5

25.5

Frontaxle

100

10.0

72.5

Frontaxlepinchbolt

23

2.3

16.5

Handlebarclampbolt

23

2.3

16.5

Handlebarsetbolt

10

1.0

7.0

Frontbrakemastercylindermountingbolt

10

1.0

7.0

Frontbrakecalipermountingbolt

25

2.5

18.1

Frontbrakecaliperhousingbolt

21

2.1

15.1

Brakehoseunionbolt

23

2.3

16.5

Clutchholdermountingbolt

10

1.0

7.0

Airbleedervalve

8.0

0.8

6.0

Brakediscbolt(Front)

23

2.3

16.5

Brakediscbolt(Rear)

35

3.5

25.5

Rearbrakecalipermountingbolt

25

2.5

18.1

Rearbrakecaliperhousingbolt

30

3.0

21.5

Rearbrakemastercylindermountingbolt

10

1.0

7.0

Rearbrakemastercylinderrodlocknut

18

1.8

13.0

Frontfootrestbracketmountingbolt

23

2.3

16.5

Swingarmpivotshaft

15

1.5

11.0

Swingarmpivotnut

100

10.0

72.5

Swingarmpivotlocknut

90

9.0

65.0

Torquelinknut(Front)

28

2.8

20.5

Torquelinknut(Rear)

34

3.4

24.6

Cushionlevermountingnut

78

7.8

56.5

Cushionrodmountingnut

78

7.8

56.5

Rearshockabsorbermountingboltandnut

(UpperandLower)

505.036.0

RearaxlenutIForE-03,28,

33

110

11.0

79.6

IFortheothers

120

12.0

86.8

Rearsprocketnut

60

6.0

43.5

Side-standmountinabracketbolt

50

5.0

36.0

Cowlinabraceboltandnut

23

2.3

16.5

Rearshockabsorberbracketnut

115

11.5

83.2

Seatrailbolt

23

2.3

16.5

TIGHTENINGTORQUECHART

Forotherboltsandnutslistedpreviously,refertothischart:

kgf.m

0.15

lb-ft

1.0

Nrn

2.3

kgf.m

0.23

lb-ft

1.5

0.3

2.0

4.5

0.45

3.0

0.55

4.0

10

1.0

7.0

1.3

9.5

23

2.3

16.5

2.9

21.0

50

5.0

36.0

4.5

32.5

85

8.5

61.5

6.5

47.0

135

13.5

97.5

10.5

76.0

210

21.0

152.0

16.0

115.5

240

24.0

173.5

....BoltDiameterConventionalor"4"markedbolt"7"markedbolt

®(mm)Nrn

41.5

53

65.5

813

1029

1245

1465

16105

18160

Conventionalbolt"4"markedboll"7"markedbolt

8·34SERVICINGINFORMATION-

SERVICEDATA

-

VALVE+GUIDEUnit:mm(in)

Valvediam.

ITEM STD/SPEC.LIMITIN.27.2

(1.07)

EX. 22(0.87)

Valveclearance(whencold)IN.0.10-0.20(0.004-0.008)

EX. 0.20-0.30(0.008-0.012)

Valveguidetovalvestemclearance

Valveguidel.D.ValvestemO.D.

IN. 0.010-0.037(0.0004-0.0015)

(0.0012

-0.0022)

4.000

-4.012

(0.1575

-0.1580)

3.975-

3.990

(0.1565-

0.1571)

3.955-

3.970

EX.0.030-0.057

IN.&EX.

IN.EX.

(0.1557-0.1563)

ValvestemdeflectionIN.&EX.0.35(0.014)

Valvestemrunout

IN.&EX.0.05(0.002)

ValveheadthicknessIN.&EX.0.5(0.02)

Valveseatwidth

Valveheadradialrunout

Valvespringfreelength

IN.&EX.0.9-1.1(0.035-0.043)

IN.&EX.0.03(0.001)

IN.&EX.37.8(1.49)

Valvespringtension173-199N

-

IN.&EX.(17.6-20.3kgf)

38.8-44.8lbs

atlength32.85mm(1.29in)

CAMSHAFT+CYLINDERHEADUnit:mm(in)ITEM STD/SPEC.LIMIT

Camheight

IN. 36.58-36.6236.28(1.440-1.442)(1.428)

EX. 35.28-35.3234.98(1.389-1.391)(1.417)

CamshaftjournaloilclearanceIN.&EX.0.032-0.0660.150(0.0013-0.0026)(0.0059)

Camshaftjournalholder1.0.

IN.&EX. 24.012-24.025(0.9454-0.9459)