Tightening of FI system and intake air system ITEM Nm kgf·m lb·ft CKP sensor mounting bolt 6.5 0.65 4.5 Fuel pump mounting bolt 10 1.0 7.0 TPS and STPS mounting screw 3.5 0.35 2.5 Fuel delivery pipe mounting screw 5 0.5 3.5 EXCVA pulley mounting bolt 5 0.5 3.5
Tightening of cooling system ITEM Nm kgf·m lb·ft Impeller securing bolt 8 0.8 6.0 Water pump mounting bolt 10 1.0 7.0 ECT sensor 18 1.8 13.0
Tightening of chassis ITEM Nm kgf·m lb·ft Handlebar clamp bolt 23 2.3 16.5 Handlebar holder bolt 85 8.5 61.5 Handlebar bracket bolt 23 2.3 16.5 Front fork upper and lower clamp bolt 23 2.3 16.5 Front fork cap bolt 23 2.3 16.5 Front fork damper rod bolt 40 4.0 29.0 Front...
Tightening torque chart For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter A (mm) Conventional or "4" marked bolt "7" marked bolt Nm kgf·m lb·ft Nm kgf·m lb·ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 10...
Service data of valve and guide Unit: mm (in) ITEM STANDARD LIMIT Valve diam. IN. 42 (1.65) — EX. 38 (1.50) — Tappet clearance (when cold) IN. 0.09 - 0.16 (0.004 - 0.006) — EX. 0.20 - 0.30 (0.008 - 0.012) — Valve guide to valve stem clearance IN. 0.010 - 0.037 (0.0004 - 0.0015) —...
Service data of camshaft and cylinder head Camshaft + cylinder head Unit: mm (in) ITEM STANDARD LIMIT Cam height IN. 40.880 - 40.930 (1.6094 - 1.6114) 40.580 (1.5976) EX. 40.880 - 40.930 (1.6094 - 1.6114) 40.580 (1.5976) Camshaft journal oil clearance IN. & EX. 0.032 - 0.066 (0.0013 -...
Service data of cylinder, piston and piston ring Unit: mm (in) ITEM STANDARD LIMIT Compression pressure (Automatic de-comp. actuated) 1 100 - 1 500 kPa (11.0 - 15.0 kgf/cm², 156 - 213 psi) 800 kPa (8.0 kgf/cm², 114 psi) Compression pressure difference — 200 kPa (2.0 kgf/cm², 28 psi) Piston to...
Service data of conrod and crankshaft Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 23.010 - 23.018 (0.9059 - 0.9062) 23.040 (0.9071) Conrod big end side clearance 0.100 - 0.200 (0.0039 - 0.0078) 0.30 (0.012) Conrod big end width 23.95 - 24.00 (0.943 - 0.945) — Crank pin width...
Service data of oil pump ITEM STANDARD LIMIT Oil pressure (at 60°C, 140°F) Above 400 kPa (4.0 kgf/cm², 57 psi) Below 700 kPa (7.0 kgf/cm², 100 psi) at 3 000 r/min —
Service data of clutch ITEM STANDARD LIMIT Clutch cable play 10 - 15 (0.4 - 0.6) — Clutch release screw 1 turn back — Drive plate thickness No. 1 3.52 - 3.68 (0.139 - 0.145) 3.22 (0.127) No. 2 1.92 - 2.08 (0.076 - 0.082) — Driven plate thickness No. 1 2.82 - 2.98 (0.111 -...
Service data of thermostat, radiator, fan and coolant ITEM STANDARD LIMIT Thermostat valve opening temperature Approx. 88°C (190°F) — Thermostat valve lift Over 8.0 mm (0.31 in) at 100°C (212°F) — Engine coolant temperature sensor resistance 20°C (68°F) Approx. 2.45 kΩ — 50°C (122°F) Approx. 0.811 kΩ —...
Service data of drive train Unit: mm (in) Expect ratio ITEM STANDARD LIMIT Primary reduction ratio 1.757 (58/33) — Secondary reduction ratio 1.058 (18/17) — Final reduction ratio 2.666 (32/12) — Gear ratio Low 2.187 (35/16) — 2nd 1.400 (28/20) — 3rd 1.038 (27/26) — 4th 0.827...
Service data of driveline/axle Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Secondary bevel gear backlush 0.03 - 0.15 (0.001 - 0.006) — Final bevel gear backlush 0.08 - 0.16 (0.003 - 0.006) — Damper spring free length — 64.6 (2.54) Final gear oil type Hypoide gear oil SAE #90,...
Service data of injector, fuel pump and fuel pressure regulator ITEM SPECIFICATION NOTE Injector resistance 11 - 13 Ω at 23°C (73°F) Fuel pump discharge amount 168 ml and more (5.7/5.9 US/lmp oz) for 10 seconds at 300 kPa (3.0 kgf/cm², 43 psi) Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0...
Service data of FI-sensors ITEM SPECIFICATION NOTE CKP sensor resistance 190 - 290 Ω CKP sensor peak voltage 1.5 V and more When cranking IAP sensor input voltage (F & R) 4.5 - 5.5 V IAP sensor output voltage (F & R) Approx. 2.6 V at idle speed TP sensor input voltage 4.5 -...
Service data of throttle body ITEM SPECIFICATION I.D. No. 48G1 (For E-33), 48G0 (Others) Bore size 56 mm Idle r/min 900±100 r/min/Warmed engine Throttle cable play 2.0 - 4.0 mm (0.08 - 0.16 in)
Service data of electrical Unit: mm (in) ITEM SPECIFICATION NOTE Firing order 1-2 Spark plug Type NGK: CR8EK DENSO: U24ETR Gap 0.6 - 0.7 (0.024 - 0.028) Spark performance Over 8 (0.3) at 1 atm. CKP sensor resistance 190 - 290 Ω Bl - G Ignition coil resistance Primary 1.8 -...
Service data of wattage Unit: W ITEM SPECIFICATION E-03, 28, 33 E-02, 19, 24 Headlight HI 60 ← LO 55 ← Position light 5 Brake light/Taillight LED ← Front turn signal light/Position light 21/5 Front turn signal light 21 Rear turn signal light 21 ← Speedometer LED ←...
Service data of brake and wheel Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 25 - 35 (1.0 - 1.4) — Brake disc thickness Front 5.0±0.2 (0.197±0.008) 4.5 (0.18) Rear 7 0 -0.4 (0.276 0 -0.016 ) 6.3 (0.25) Brake disc runout (Front & Rear) — 0.30 (0.012) Master cylinder...
Service data of suspension Unit: mm (in) ITEM STANDARD LIMIT Front fork stroke 130 (5.1) — Front fork spring free length 399 (15.7) 391 (15.4) Front fork inner tube O.D. 46 (1.8) — Front fork oil level (without spring, inner tube fully compressed) 133 (5.2) — Front fork oil...
Service data of tire pressure COLD INFLATION TIRE PRESSURE SOLO RIDING DUAL RIDING kPa kgf/cm² psi kPa kgf/cm² psi FRONT 250 2.50 36 250 2.50 36 REAR 290 2.90 42 290 2.90 42
Service data of fuel and oil ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2). Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion...