Kawasaki ER5 (2004) User Manual [ru]

Name: Kawasaki ER5 (2004)
Brand: Kawasaki
SKU: 2686892
Rating: 4.5 (2 reviews)

4.5 (2)

Quick Reference Guide

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.

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

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 in 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 make 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 are intended for reference use only and may not depict actual model component parts.

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	bottom dead center	PS	horsepower
BTDC	before top dead center	psi	pound(s) per square inch
°C	degree(s) Celsius	r	revolution
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)

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. Instead, 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 "remove or render inoperative any device or element of design" has been generally interpreted as follows:

1.Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.

2.Tampering could include:

a.Maladjustment of vehicle components such that the emission standards are exceeded.

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 standards.

d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

TAMPERING WITH NOISE 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 Motorcycle 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 carefully. Don’t take shortcuts.

•Remember to keep complete records of maintenance and repair with dates and any new parts installed.

How to Use This Manual

In this manual, the product is 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 personal injury, or loss of life.

CAUTION

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage 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 particular interest for more efficient and convenient operation.

•Indicatesdone. a procedural step or work to be ○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 inspection in the procedural step or sub-step it follows.

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
General Information		1
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

1-2 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 should 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.

GENERAL INFORMATION 1-5

Model Identification

ER500-C1, D1 Left Side View

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	179 kg (395 lb.)	←	←
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
			PS) @8 000
			r/min (rpm)
Maximum Torque	45 N·m (4.6 kgf·m, 33 ft·lb) @7 200	←	37 N·m (3.8
	r/min (rpm)		kgf·m, 27
			ft·lb) @4 500
			r/min (rpm)
Carburetion System	Carburetors, Keihin CVK34 × 2	←	←
Starting System	Electric starter	←	←
Ignition System	Battery and coil (transistorized)	←	←
Timing Advance	Electronically Advanced (digital)	←	←
Ignition Timing	From 10° BTDC @1 200 r/min (rpm)	←	←
	to 37.5° BTDC @10 000 r/min (rpm)
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°	←	←

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	SAE10W-40	←	←
Capacity	3.4 L (3.6 us at)	←	←
Drive Train
Primary Reduction System:
Type	Chain	←	←
Reduction Ratio	2.652 (61/23)	←	←
Clutch Type	Wet multi disc	←	←
Transmission:
Type	6-speed constant mesh, return shift	←	←
Gear Ratios:
1st	2.571 (36/14)	←	←
2nd	1.722 (31/18)	←	←
3rd	1.333 (28/21)	←	←
4th	1.125 (27/24)	←	←
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	102 mm (4.02 in.)	←	←
Front Tire:
Type	Tubeless	←	←
Size	110/70-17 54H	110/70-17	110/70-17
		M/C 54H	54H
Rear Tire:
Type	Tubeless	←	←
Size	130/70-17 62H	130/70-17	130/70-17
		M/C 62H	62H
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	←	←

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

* ODOMETER READING

comes

× 1 000 km

first

(× 1 000 mile)

Remarks

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 †

•

before 2005

Valve clearance - inspect †

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

* ODOMETER READING

comes

× 1 000 km

first

(× 1 000 mile)

Remarks

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

4 years

dust seal - replace

Caliper piston seal and dust seal

4 years

- replace

Front Fork oil - change

2 years

•

#: Service more frequently when operating in severe conditions; 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.

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					Torque				Remarks
Fastener			N·m		kgf·m	ft·lb			Remarks
			N·m		kgf·m	ft·lb
Fuel System
Fuel Tap Plate Screws			0.8		0.08	7 in·lb
Fuel Tap Diaphragm Chamber Screws			1.0		0.10	9 in·lb
Fuel Tap Mounting Bolts			2.5		0.25	22 in·lb
Fuel Level Sensor Bolts			6.9		0.7	61 in·lb
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 Pump Impeller			9.8		1.0	87 in·lb			Lh

1-12 GENERAL INFORMATION

Torque and Locking Agent

Fastener		Torque			Remarks
Fastener	N·m	kgf·m	ft·lb		Remarks
	N·m	kgf·m	ft·lb
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	11	1.1	95	in·lb
Engine Top End
Spark Plugs	14	1.4	10
Cylinder Head Cover Bolts	9.8	1.0	87	in·lb
Camshaft Cap Bolts	12	1.2	8.5		S
Rocker Shafts
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	12	1.2	8.5
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)	11	1.1	95	in·lb
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	11	1.1	95	in·lb
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
					(Planted
					side)
Oil Filter (Cartridge Type)	17	1.75	12.5
Oil Pipe for Balancer Shaft Banjo Bolt	20	2.0	14.5
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	11	1.1	95 in·lb		L
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

GENERAL INFORMATION 1-13

Torque and Locking Agent

Fastener		Torque			Remarks
Fastener	N·m	kgf·m	ft·lb		Remarks
	N·m	kgf·m	ft·lb
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)	27	2.8	20		S
Crankcase Bolts (6 mm)	12	1.2	8.5		S
Upper Primary Chain Guide Mounting Nut			95 in·lb		L
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	–	–		–	L
					(planted
					side)
Gear Positioning Lever Nut	11	1.1	95	in·lb
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	15	1.5		11
Wheels/Tires
Front Axle Nut	88	9.0	65
Front Axle Clamp Bolt	20	2.0	14.5
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
					(planted
					side)
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	9 in·lb
Brake Lever Pivot Locknut	5.9	0.60	52	in·lb
Master Cylinder Clamp Bolts	8.8	0.9	78	in·lb	S

1-14 GENERAL INFORMATION

Torque and Locking Agent

Fastener		Torque			Remarks
Fastener	N·m	kgf·m	ft·lb		Remarks
	N·m	kgf·m	ft·lb
Front Brake Light Switch Mounting Screw	1.2	0.12	10	in·lb
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	35	3.6	26
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	34	3.5	25
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	Hand	Hand
	-Tighten	-Tighten	-Tighten
	(about 4.9)	(about 0.5)	(about 43
			in·lb)
Frame
Tail Grip Bolts	25	2.5	18
Footpeg Bracket Bolts	34	3.5	25
Sidestand Bolt and Nut
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				in·lb
Alternator Cover Bolts	11	1.1	95	in·lb
Alternator Cover Allen Bolt	13	1.3	9.5
Alternator Lead Clamp Screws	2.9	0.30	26	in·lb
Spark Plug	14	1.4	10
Alternator Stator Allen Bolts	12	1.2	8.5
Alternator Rotor Bolt	69	7.0	51
Starter Motor Mounting Bolts	11	1.1	95	in·lb
Starter Chain Guide Screws	4.9	0.5	43	in·lb	L
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

GENERAL INFORMATION 1-15

Torque and Locking Agent

Fastener		Torque			Remarks
Fastener	N·m	kgf·m	ft·lb		Remarks
	N·m	kgf·m	ft·lb
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	6.9	0.70	61	in·lb
Starter Relay Terminal Bolt	4.9	0.50	43	in·lb
Headlight Body Screws				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	7.8	0.80	69 in·lb		SS
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

1-16 GENERAL INFORMATION

Special Tools and Sealants

Piston Ring Pliers: 57001-115

Inside Circlip Pliers: 57001-143

Oil Pressure Gauge, 5 kgf/cm²: 57001-125

Outside Circlip Pliers: 57001-144

Bearing Puller: 57001-135

Bearing Puller: 57001-158

Bearing Puller Adapter: 57001-136

Fork Cylinder Holder Handle: 57001-183

Steering Stem Bearing Driver: 57001-137

Compression Gauge, 20 kgf/cm²: 57001-221

		GENERAL INFORMATION 1-17
Special Tools and Sealants

Valve Spring Compressor Assembly:		Valve Guide Arbor,	5.5:
Valve Spring Compressor Assembly:		Valve Guide Arbor,	5.5:
57001-241	57001-1021

Bearing Puller Adapter: 57001-317

Spark Plug Wrench, Hex 18: 57001-1024

Bearing Driver, 32: 57001-382

Fork Cylinder Holder Adapter: 57001-1057

Piston Pin Puller Assembly: 57001-910

Oil Seal & Bearing Remover: 57001-1058


Fuel Level Gauge:		Rim Protector:
57001-1017	57001-1063

1-18 GENERAL INFORMATION

Special Tools and Sealants

Bead Breaker Assembly:		Piston Ring Compressor Grip:
57001-1072	57001-1095

Steering Stem Bearing Driver Adapter, 34.5: 57001-1074

Piston Ring Compressor Belt, 67 79:

57001-1097

Head Pipe Outer Race Press Shaft: 57001-1075

Steering Stem Nut Wrench: 57001-1100

Head Pipe Outer Race Driver, 51.5: 57001-1076

Head Pipe Outer Race Driver, 46.5: 57001-1106

Valve Guide Reamer, 5.5: 57001-1079

Valve Seat Cutter, 45° - 24.5: 57001-1113

			GENERAL INFORMATION 1-19
Special Tools and Sealants

Valve Seat Cutter, 32° -	25:		Bearing Driver Set:
Valve Seat Cutter, 32° -	25:		Bearing Driver Set:
57001-1118		57001-1129