Kawasaki ER5 (2004) User Manual [ru]
Quick Reference Guide
General Information 1 j
Fuel System 2 j
Cooling System 3 j
Engine Top End 4 j
Clutch 5 j
Engine Lubrication System 6 j
Engine Removal/Installation 7 j
Crankshaft/Transmission 8 j
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.
Wheels/Tires 9 j
Final Drive 10 j
Brakes 11 j
Suspension 12 j
Steering 13 j
Frame 14 j
Electrical System 15 j
Appendix 16 j
ER-5
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted i n any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Department/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to m ake it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication a re intended for reference use only and may
not depict actual model component parts.
© 2000 Kawasaki Heavy Industries, Ltd. 4th Edition (1): Aug. 5, 2004 (K)
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC
BTDC before top dead center
°C degree(s) Celsius
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
bottom dead center
PS
psi
r revolution
horsepower
pound(s) per square inch
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the carburetion system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..."
NOTE
The phrase "re move or render inoperative any device or e lement of design" has been generally
○
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of de vices or elements o f design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE TH ESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.
TAMPERING WITH N OISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below:
Replacement of the original exhaust system or muffler with a component not in compliance
•
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
•
Removal of the air box or air box cover.
•
Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such
•
modifications result in increased noise levels.
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
•
Service Manual.
Be alert for problems and non-scheduled
•
maintenance.
Use proper tools and genuine Kawasaki Mo-
•
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Special Tool Catalog or Manual. Genuine
parts provided as spare parts are listed in the
Parts Catalog.
Follow the procedures in this manual care-
•
fully. Don’t take shortcuts.
Remember to keep complete records of main-
•
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product i s divided into its
major systems and these systems make up the
manual’s chapters.
The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the ignition coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
This note symbol indicates points of par-
○
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
○
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-5
General Specifications............................................................................................................ 1-6
Periodic Maintenance Chart ................................................................................................... 1-9
Torque and Locking Agent...................................................................................................... 1-11
Special Tools and Sealants .................................................................................................... 1-16
Cable, Wire, and Hose Routing .............................................................................................. 1-23
1
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten
the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or
metal filings.
(2) Battery Ground
Disconnect the ground (–) wire from the battery before performing any disassembly operations
on the motorcycle. This prevents the engine from accidentally turning over while work is being
carried out, sparks from being generated while disconnecting the wires from electrical parts, as
well as damage to the electrical parts themselves. For reinstallation, first connect the positive
wire to the positive (+) terminal of the battery
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and
cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever
possible.
(4) Tightening Sequence
When installing bolts, nuts, or screws for which a tightening sequence is given in this Service
Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or
screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has
been installed in its proper location. Then, tighten them to the specified torque in the tightening
sequence and method indicated. If tightening sequence instructions are not given, tighten them
evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws
that are retaining the part a 1/4-turn before removing them.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removing screws held by non-permanent locking
agent) in order to avoid damaging the screw heads.
(7) Edges
Watch for sharp edges, as they could cause injury through careless handling, especially during
major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine
or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(9) Gasket, O-ring
Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter
from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent
oil or compression leaks.
GENERAL INFORMATION 1-3
Before Servicing
(10)Liquid Gasket, Locking Agent
Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used.
Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage.
(11) Press
When using a press or driver to install a part such as a wheel bearing, apply a small amount of
oil to the area where the two parts come in contact to ensure a smooth fit.
(12)Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any
ball or needle bearings that were removed with new ones. Install bearings with the manufacturer
and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the
end of the race that contacts the press fit portion, and press it evenly over the base component.
(13)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a
force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless
instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks,
press it in with the marks facing out.
(14)Circlip, Retaining Ring, and Cotter Pin
When installing circlips and retaining rings, take care to compress or expand them only enough
to install them and no more. Install the circlip with its chamfered side facing load side as well.
Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while
the motorcycle is driven, leading to a major problem.
(15)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the sliding
surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding
surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative
quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off
and apply fresh grease or oil. Some oils and greases in particular s hould be used only in certain
applications and may be harmful if used in an application for which they are not intended.
(16)Direction of Engine Rotation
To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper
adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as
well.
(17)Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed.
Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and
cotter pin have not been so designated in their respective text, they are replacement parts.
(18)Electrical Wires
All the electrical wires are either one-color or two-color. A two-color wire is identified first by the
primary color and then the stripe color. For example, a yellow wire with thin red stripes is referred
to as a “yellow/red” wire; it would be a “red/yellow” wire if the colors were reversed. Unless instructed otherwise, electrical wires must be connected to wires of the same color.
1-4 GENERAL INFORMATION
Before Servicing
Two-Color Electrical
(19)Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(20)Specifications
Specification terms are defined as follows:
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. If the measurement shows excessive wear or dete-
riorated performance, replace the damaged parts.
Model Identification
ER500-C1, D1 Left Side View
GENERAL INFORMATION 1-5
ER500-C1, D1 Right Side View
1-6 GENERAL INFORMATION
General Specifications
Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1
Dimensions
Overall Length 2 070 mm (81.5 in.) ← ←
Overall Width 730 mm (28.74 in.) ← ←
Overall Height 1 070 mm (42.13 in.) ← ←
Wheelbase 1 430 mm (56.3 in.) ← ←
Road Clearance 125 mm (4.92 in.) ← ←
Seat Height 800 mm (31.5 in.)
Dry Weight
Curb Weight:
Front 92 kg (203 lb.) ← ←
Rear 107 kg (236 lb.) ← ←
Fuel tank Capacity 17 L (4.5 US gal.) ← ←
Performance
Minimum Turning Radius 2.5 m (8.2 ft.) ← ←
Engine
Type 4-stroke, DOHC, 2-cylinder ← ←
Cooling System Liquid-cooled ← ←
Bore and Stroke 74.0 × 58.0 mm (2.91 × 2.28 in.) ← ←
Displacement 498 mL (30.39 cu in.) ← ←
Compression Ratio 9.8:1 ← ←
Maximum Horsepower 37 kW (50.3 PS) @9 000 r/min (rpm) ← 25 kW (34
Maximum Torque 45 N·m (4.6 kgf·m, 33 ft·lb) @7 200
Carburetion System Carburetors, Keihin CVK34 × 2 ← ←
Starting System Electric starter ← ←
Ignition System Battery and coil (transistorized) ← ←
Timing Advance Electronically Advanced (digital) ← ←
Ignition Timing
Spark Plugs NGK DR9EA or ND X27ESR-U ← ←
Cylinder Numbering Method Left to right, 1-2 ← ←
Firing Order 1-2 ← ←
Valve Timing:
Inlet
Open 31° BTDC ← ←
Close 51° ABDC ← ←
DuRation 262° ← ←
Exhaust
Open 56° BBDC ← ←
Close 26° ATDC ← ←
DuRation 262° ← ←
179 kg (395 lb.)
r/min (rpm)
From 10° BTDC @1 200 r/min (rpm)
to 37.5° BTDC @10 000 r/min (rpm)
← ←
← ←
PS) @8 000
r/min (rpm)
← 37 N·m (3.8
kgf·m, 27
ft·lb) @4 500
r/min (rpm)
← ←
GENERAL INFORMATION 1-7
General Specifications
Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1
Lubrication System Forced lubrication ← ←
Engine Oil:
Grade API SE, SF, SG or
API SH or SJ with JASO MA
Viscosity
Capacity 3.4 L (3.6 us at)
Drive Train
Primary Reduction System:
Type Chain ← ←
Reduction Ratio
Clutch Type
Transmission:
Type 6-speed constant mesh, return shift ← ←
Gear Ratios:
1st 2.571 (36/14) ← ←
2nd
3rd
4th
5th 0.961 (25/26) ← ←
6th 0.851 (23/27) ← ←
Final Drive System:
Type Chain drive ← ←
Reduction Ratio 2.470 (42/17) ← ←
Overall Drive Ratio 5.581 @Top gear ← ←
Frame
Type Tubular, double cradle ← ←
Caster (rake angle) 27° ← ←
Trail
Front Tire:
Type Tubeless ← ←
Size 110/70-17 54H 110/70-17
Rear Tire:
Type Tubeless ← ←
Size 130/70-17 62H 130/70-17
Front Suspension:
Type Telescopic fork ← ←
Wheel Travel 125 mm (4.92 in.) ← ←
Rear Suspension:
Type Swingarm ← ←
Wheel Travel 114 mm (4.49 in.) ← ←
Brake Type:
Front Single disc ← ←
Rear Drum ← ←
SAE10W-40
2.652 (61/23)
Wet multi disc ← ←
1.722 (31/18)
1.333 (28/21)
1.125 (27/24)
102 mm (4.02 in.)
← ←
← ←
← ←
← ←
← ←
← ←
← ←
← ←
M/C 54H
M/C 62H
110/70-17
54H
130/70-17
62H
1-8 GENERAL INFORMATION
General Specifications
Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1
Electrical Equipment
Battery 12 V 10 Ah ← ←
Headlight:
Type Semi-sealed beam ← ←
Bulb 12 V 60/55 W (quartz-halogen) ← ←
Tail/brake Light 12 V 5/21 W × 2 ← ←
Alternator:
Type Three-phase AC ← ←
Rated output 17 A × 14 V @6 000 r/min (rpm) ← ←
Specifications subject to change without notice, and may not apply to every country.
GENERAL INFORMATION 1-9
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition. The initial maintenance is vitally important and must not be neglected.
FREQUENCY Whichever
comes
first
1 6 12 18 24 30 36
INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24)
Throttle cable - inspect †
Idle speed - inspect †
Carburetor synchronization inspect †
Air cleaner element - clean† #
Fuel hoses, connections - inspect
†
Coolant filter - clean years
Radiator hoses, connections inspect †
Air suction valve - inspect †
• • • •
• • • •
• • •
• • •
• • • • • •
•
• • • • • •
* O DOMETER READING
• • •
Valve clearance - inspect †
•
× 1 000 km
(× 1 000 mile)
Remarks
before 2005
model
after 2005
model
Clutch adjust - inspect †
Tire wear - inspect †
Drive chain wear - inspect †#
Drive chain - lubricate # 600 km
Drive chain slack - inspect †# 1000 km
Brake Play - inspect †#
Brake fluid level - inspect † month
Brake hoses, connections inspect †
Brake lining or pad wear - inspect
†#
Brake light switch - inspect †
Front fork oil leak - inspect †
Rear shock absorber oil leak inspect †
Swingarm pivot - lubricate
Steering - inspect †
Steering stem bearing - lubricate 2 years
Spark plug - clean and gap †
General lubrication - perform
Nut, bolts, and fasteners tightness
- inspect †
• • • • • • •
• • • • • •
• • • • • •
• • • • • • •
• • • • • • •
• • • • • •
• • • • • •
• • • • • • •
• • •
• • •
• • •
• • • • • • •
•
• • • • • •
• • •
• • • •
Coolant - change 2 years
•
1-10 GENERAL INFORMATION
Periodic Maintenance Chart
FREQUENCY Whichever
comes
first
1 6 12 18 24 30 36
INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24)
Engine oil - change # year
Oil filter - replace
Brake fluid - change 2 years
Brake master cylinder cup and
dust seal - replace
Caliper piston seal and dust seal
- replace
Front Fork oil - change 2 years
#: Service m ore frequently when operating in severe c onditions; dusty, wet, muddy, high speed,
or frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
†: Replace, add, adjust, clean, or torque if necessary.
4 years
4 years
• • • • • • •
• • • •
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
Remarks
•
•
GENERAL INFORMATION 1-11
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently
tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle
and injury to the rider. A bolt or nut which is overtightened may become damaged, strip an internal
thread, or break and then fall out. The following table lists the tightening torque for the major bolts
and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn
and then tighten it to the specified torque.
Letters used in the "Remarks" column mean:
L: Apply a non-permanent locking agent to the threads.
LG: Apply liquid gasket to the threads.
Lh: Left-hand threads.
M: Apply molybdenum disulfide grease.
O: Apply an oil to the threads and seating surface.
R: Replacement parts.
S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant to the threads.
St: Stake the fasteners to prevent loosening.
The table relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
Use this table for only the bolts and nuts which do not require a specific torque value. All of the values
are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads Torque
dia. (mm) N·m kgf·m ft·lb
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼19 1.4 ∼1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240
Fastener
Fuel System
Fuel Tap Plate Screws
Fuel Tap Diaphragm Chamber S crews 1.0 0.10 9in·lb
Fuel Tap Mounting Bolts 2.5 0.25 22 in·lb
Fuel Level Sensor Bolts
Cooling System
Radiator Hose Clamp Screws 2.5 0.25 22 in·lb
Fan Switch 18 1.8 13
Thermostat Housing Bolts 11 1.1 95 in·lb
Water Temperature Sensor 7.8 0.8 69 in·lb SS
Water Pump Cover Bolts 11 1.1 95 in·lb
Water Pump Shaft 25 2.5 18 Lh
Water P ump Impeller 9.8 1.0 87 in·lb Lh
N·m kgf·m ft·lb
0.8 0.08 7in·lb
6.9 0.7 61 in·lb
Torque
Remarks
1-12 GENERAL INFORMATION
Torque and Locking Agent
Fastener
Water Pipe Bolts 9.8 1.0 87 in·lb L
Cylinder Head Jacket Plug 9.8 1.0 87 in·lb L
Air Suction Valve Cover Bolts 11 1.1 95 in·lb
Coolant Drain Plug
Engine Top End
Spark Plugs 14 1.4 10
Cylinder Head Cover Bolts
Camshaft Cap Bolts 12 1.2 8.5 S
Rocker Shafts 39 4.0 29
Valve Adjuster Locknuts 25 2.5 18
Camshaft Sprocket Bolts 15 1.5 11 L
Cylinder Head Bolts (10 mm) 51 5.2 38 S
Cylinder Head Bolts (6 mm) 9.8 1.0 87 in·lb S
Cam Chain Tensioner Mounting Bolts 11 1.1 95 in·lb
Cam Chain Tensioner Cap Bolt 13 1.3 9.5
Main Oil Pipe Upper Banjo Bolts M8
Main Oil Pipe Lower Banjo Bolt M10 20 2.0 14.5
Water Pipe Bolts 9.8 1.0 87 in·lb L
Oil Pipe Bolts (in the cylinder head)
Oil Pipe Mounting Bolt 11 1.1 95 in·lb
Clutch
Oil Filler Plug 1.5 0.15 13 in·lb
Clutch Hub Nut 132 13.5 98
Clutch Spring Bolts 9.3 0.95 82 in·lb
Clutch Cable Holder Bolt
Clutch Cover Bolts 11 1.1 95 in·lb
Engine Lubrication System
Oil Filler Plug 1.5 0.15 13 in·lb
Oil Passage Plug 18 1.8 13
Oil Filter Mounting Stud 25 2.5 18 L
Oil Filter (Cartridge Type) 17 1.75 12.5
Oil Pipe for Balancer Shaft Banjo Bolt
Oil Pipe for Drive Shaft Upper Banjo Bolt M6 7.8 0.8 69 in·lb
Oil Pipe for Drive Shaft Lower Banjo Bolt M8 12 1.2 8.5
Oil Pipe for Output Shaft Upper Banjo Bolt M6 7.8 0.8 69 in·lb
Oil Pipe for Output Shaft Lower Banjo Bolt M8 12 1.2 8.5
Oil Pipe for Output Shaft Mounting Bolt 11 1.1 95 in·lb L
Oil Pump Pipe Mounting Bolts
Relief Valve 15 1.5 11 L
Oil Pressure Switch Terminal Bolt 15 0.15 13 in·lb
Oil Pressure Switch 15 1.5 11 SS
N·m kgf·m ft·lb
11 1.1 95 in·lb
9.8 1.0 87 in·lb
12 1.2 8.5
11 1.1 95 in·lb
11 1.1 95 in·lb
20 2.0 14.5
11 1.1 95 in·lb L
Torque
Remarks
(Planted
side)
Torque and Locking Agent
GENERAL INFORMATION 1-13
Fastener
Engine Oil Drain Plug 29 3.0 22
Oil Pan Mounting Bolts 11 1.1 95 in·lb
Oil Pump Mounting Bolts 11 1.1 95 in·lb
Breather Body Bolt 5.9 0.6 52 in·lb
Engine Removal/Installation
Downtube Bolts 44 4.5 33
Engine Mounting Bolts and Nuts 44 4.5 33
Engine Mounting Bracket Bolts 25 2.5 18
Crankshaft/Transmission
Crankcase Bolts (8 mm)
Crankcase Bolts (6 mm) 12 1.2 8.5 S
Upper Primary Chain Guide Mounting Nut 11 1.1 95 in·lb L
Lower Primary Chain Guide Mounting Bolt 11 1.1 95 in·lb L
Connecting Rod Big End Nuts 36 3.7 27
Return Spring Pin 20 2.0 14.5 L
Gear Positioning Lever Pivot Stud
Gear Positioning Lever Nut
Shift Pedal Mounting Bolt 12 1.2 8.5
Shift Drum Bearing Holder Bolts 11 1.1 95 in·lb L
Shift Drum Cam Pin Plate Screw – – – L
Engine Sprocket Nut 127 13 94 O
External Shift Mechanism Cover Bolts 11 1.1 95 in·lb
Neutral Switch
Wheels/Tires
Front Axle Nut 88 9.0 65
Front Axle Clamp Bolt
Rear Axle Nut 98 10 72
Final Drive
Torque Link Nuts 34 3.5 25
Engine Sprocket Nut 127 13 94 O
Rear Sprocket Nuts 59 6.0 43
Rear Coupling Studs – – – L
Engine Axle Nut 98 10 72
Drive Chain Guide Bolts 11 1.1 95 in·lb
Brakes
Brake Hose Banjo Bolts 25 2.5 18
Reservoir Cap Screws 1.5 0.15 13 in·lb
Brake Lever Pivot Bolt 1.0 0.10 9in·lb
Brake Lever Pivot Locknut 5.9 0.60 52 in·lb
Master Cylinder Clamp Bolts 8.8 0.9 78 in·lb S
N·m kgf·m ft·lb
27 2.8 20
– – – L
11 1.1 95 in·lb
15 1.5 11
20 2.0 14.5
Torque
Remarks
S
(planted
side)
(planted
side)
1-14 GENERAL INFORMATION
Torque and Locking Agent
Fastener
Front Brake Light Switch Mounting Screw
Caliper Mounting Bolts 34 3.5 25
Caliper Bleed Valves 7.8 0.8 69 in·lb
Brake Disc Mounting Bolts 27 2.8 20 L
Brake Pedal Bolt 8.8 0.9 78 in·lb
Torque Link Nuts 34 3.5 25
Brake Cam Lever Bolt 19 1.9 13.5
Suspension
Front Fork Upper Clamp Allen Bolts 20 2.0 14.5
Front Fork Lower Clamp Allen Bolts
Front Fork Bottom Allen Bolt 20 2.0 14.5 L
Front Axle Clamp Bolt 20 2.0 14.5
Rear Shock Absorber Bolts and Nuts
Swing Arm Pivot Nut 88 9.0 65
Steering
Handlebar Clamp Bolts 25 2.5 18 S
Handlebar Weight Allen Bolts – – – L
Handlebar Switch Housing Screws 3.4 0.35 30 in·lb
Steering Stem Head Bolt 44 4.5 33
Steering Stem Nut Hand
Frame
Tail Grip Bolts 25 2.5 18
Footpeg Bracket Bolts 34 3.5 25
Sidestand Bolt and Nut 44 4.5 33
Center Stand Bolt and Nut 44 4.5 33
Electrical System
Pickup Coil Mounting Allen Bolts 8.3 0.85 74 in·lb L
Timing Inspection Plug 2.5 0.25 22 in·lb
Alternator Rotor Bolt Plug 1.5 0.15 13 in·lb
Alternator Cover Bolts 11 1.1 95 in·lb
Alternator Cover Allen Bolt 13 1.3 9.5
Alternator Lead Clamp S crews 2.9 0.30 26 in·lb
Spark Plug 14 1.4 10
Alternator Stator Allen Bolts
Alternator Rotor Bolt 69 7.0 51
Starter Motor Mounting Bolts 11 1.1 95 in·lb
Starter Chain Guide Screws
Starter Motor Through Bolts 6.9 0.7 65 in·lb
Starter Motor Terminal Nut 4.9 0.5 43 in·lb
Starter Motor Lead Clamp Nut 4.9 0.5 43 in·lb
N·m kgf·m ft·lb
1.2 0.12 10 in·lb
35 3.6 26
34 3.5 25
-Tighten
(about 4.9) (about 0.5) (about 43
12 1.2 8.5
4.9 0.5 43 in·lb L
Torque
Hand
-Tighten
Hand
-Tighten
in·lb)
Remarks
Torque and Locking Agent
GENERAL INFORMATION 1-15
Fastener
Starter Clutch Allen Bolts 34 3.5 25 L
Sidestand Switch Mounting Screw 3.9 0.4 35 in·lb L
Sidestand Mounting Bolt 44 4.5 33
Starter Motor Terminal Locknut
Starter Relay Terminal Bolt 4.9 0.50 43 in·lb
Headlight Body Screws 2.9 0.30 26 in·lb
Handlebar Switch Housing Screws 3.4 0.35 30 in·lb
Radiator Fan Switch 18 1.8 13
Meter Reset Knob Screw – – – L
Water Temperature Switch
Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb
Oil Pressure Switch 15 1.5 11 SS
Neutral Switch 15 1.5 11
Tail Light Mounting Nut 5.9 0.6 52 in·lb
N·m kgf·m ft·lb
6.9 0.70 61 in·lb
7.8 0.80 69 in·lb
Torque
Remarks
SS
1-16 GENERAL INFORMATION
Special Tools and Sealants
Piston Ring Pliers:
57001-115
Oil Pressure Gauge, 5 kgf/cm²:
57001-125
Bearing Puller:
57001-135
Inside Circlip Pliers:
57001-143
Outside Circlip Pliers:
57001-144
Bearing Puller:
57001-158
Bearing Puller Adapter:
57001-136
Steering Stem Bearing Driver:
57001-137
Fork Cylinder Holder Handle:
57001-183
Compression Gauge, 20 kgf/cm²:
57001-221
Special Tools and Sealants
GENERAL INFORMATION 1-17
Valve Spring Compressor Assembly:
57001-241
Bearing Puller Adapter:
57001-317
Bearing Driver, 32:
57001-382
Valve Guide Arbor, 5.5:
57001-1021
Spark Plug Wrench, Hex 18:
57001-1024
Fork Cylinder Holder Adapter:
57001-1057
Piston Pin Puller A ssembly:
57001-910
Fuel Level Gauge:
57001-1017
Oil Seal & Bearing Remover:
57001-1058
Rim Protector:
57001-1063
1-18 GENERAL INFORMATION
Special Tools and Sealants
Bead Breaker Assembly:
57001-1072
Steering Stem Bearing Dri ve r Adapter, 34.5:
57001-1074
Head Pipe Outer Race Press Shaft:
57001-1075
Piston Ring Compressor Grip:
57001-1095
Piston Ring Compressor Belt, 67 ∼ 79:
57001-1097
Steering Stem Nut Wrench:
57001-1100
Head Pipe Outer Race Driver, 51.5:
57001-1076
Valve Guide Reamer, 5.5:
57001-1079
Head Pipe Outer Race Driver, 46.5:
57001-1106
Valve Seat Cutter, 45° - 24.5:
57001-1113
Special Tools and Sealants
GENERAL INFORMATION 1-19
Valve Seat Cutter, 32° - 25:
57001-1118
Valve Seat Cutter, 32° - 30:
57001-1120
Valve Seat Cutter, 60° - 30:
57001-1123
Bearing Driver Set:
57001-1129
Compression Gauge Adapter, M12 × 1.25:
57001-1183
Valve Seat Cutter, 45° - 30:
57001-1187
Valve Seat Cutter Holder, 5.5:
57001-1125
Valve Seat Cutter Holder Bar:
57001-1128
Valve Spring Compressor Adapter, 22:
57001-1202
Oil Pressure Gauge Adapter, M14 × 1.5:
57001-1209
1-20 GENERAL INFORMATION
Special Tools and Sealants
Rotor Puller, M16/M18/M20/M22 × 1.5:
57001-1216
Fork Outer Tube Weight:
57001-1218
Front Fork Oil Seal Driver:
57001-1219
Clutch Holder:
57001-1243
Oil Filter Wrench:
57001-1249
Bearing Remover Head, 15 × 17:
57001-1267
Jack:
57001-1238
Timing Light:
57001-1241
Carburetor Drain Plug Wrench, Hex 3:
57001-1269
Fork Oil Level Gauge:
57001-1290
Pilot Screw Adjuster, C:
57001-1292
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