Basic Torque for General Fasteners

 

Threads Diameter				Torque
(mm)	N·m	kgf·m	ft·lb
	3.4	∼	4.9	0.35	∼	0.50	30 ∼	43 in·lb
	5.9	∼	7.8	0.60	∼	0.80	52 ∼	69 in·lb
		∼		1.4	∼	1.9	10.0 ∼	13.5
		∼		2.6	∼	3.5	19.0 ∼
		∼		4.5	∼	6.2		∼
		∼		7.4 ∼	10.0		∼
		∼		11.5	∼	16.0	83 ∼
		∼		17.0	∼	23.0		∼
		∼		23.0	∼	33.0		∼

 

			PERIODIC MAINTENANCE 2-11
Specifications
Item		Standard		Service Limit
Fuel System (DFI)
Throttle Grip Free Play	2 ∼ 3 mm (0.08 ∼ 0.12 in.)		– – –
Idle Speed	1 300 ±50 r/min (rpm)		– – –
Bypass Screws (Turn Out)	0 ∼ 2 1/2 (for reference)		– – –
Engine Vacuum	35.3 ±1.3 kPa (265 ±10 mmHg)	– – –
Air Cleaner Element	Polyurethane Foam		– – –
Cooling System
Coolant:
Type (recommended)	Permanent type of antifreeze	– – –
Color	Green			– – –
Mixed Ratio	Soft water 50%, Coolant 50%	– – –
Freezing Point	–35°C (–31°F)		– – –
Total Amount	1.2 L (1.3 US qt)		– – –
Engine Top End
Valve Clearance:
Exhaust	0.22 ∼	0.31 mm (0.0087 ∼	0.0122 in.)	– – –
Inlet	0.15 ∼	0.21 mm (0.0059 ∼	0.0083 in.)	– – –
Clutch
Clutch Lever Free Play	2 ∼ 3 mm (0.08 ∼ 0.12 in.)		– – –
Engine Lubrication System
Engine Oil:
Type	API SE, SF or SG		– – –
	API SH, SJ or SL with JASO MA
Viscosity	SAE 10W-40		– – –
Capacity	1.7 L (1.8 US qt) (when filter is not	– – –
	removed)
	1.9 L (2.0 US qt) (when filter is removed)	– – –
	2.4 L (2.5 US qt) (when engine is	– – –
	completely dry)
Level	Between upper and lower level lines	– – –
	(after idling or running)
Wheels/Tires
Tread Depth:
Front	4.3 mm (0.17 in.)		1 mm (0.04 in.),
				(AT, CH, DE)
				1.6 mm (0.06 in.)
Rear	7.0 mm (0.28 in.)		Up to 130 km/h (80 mph):
				2 mm (0.08 in.),
				Over 130 km/h (80 mph):
				3 mm (0.12 in.)
Air Pressure (when Cold):
Front	Up to 180 kg (397 lb) load:	– – –
	225 kPa (2.25 kgf/cm², 32 psi)
Rear	Up to 180 kg (397 lb) load:	– – –
	250 kPa (2.50 kgf/cm², 36 psi)

 

PERIODIC MAINTENANCE

 

Specifications

 

Item	Standard	Service Limit
Final Drive
Drive Chain Slack	30 ∼ 40 mm (1.2 ∼ 1.6 in.)	– – –
Drive Chain Wear (20-link	317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)	323 mm (12.7 in.)
Length)
Standard Chain:
Make	ENUMA	– – –
Type	EK520MVXL1	– – –
Link	114 links	– – –
Brakes
Brake Fluid:
Grade	DOT4	– – –
Brake Pad Lining
Thickness:
Front	4.5 mm (0.18 in.)	1 mm (0.04 in.)
Rear	5.0 mm (0.20 in.)	1 mm (0.04 in.)
Brake Light Timing:
Front	Pulled ON	– – –
Rear	ON after about 10 mm (0.39 in.) of	– – –
	pedal travel
Electrical System
Spark Plug Gap	0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.)	– – –

 

		PERIODIC MAINTENANCE 2-13
Special Tools
Inside Circlip Pliers:		Extension Tube:
57001-143	57001-1578

 

Steering Stem Nut Wrench: 57001-1100

Pilot Screw Adjuster, E: 57001-1603

 

 

Oil Filter Wrench: 57001-1249

 

PERIODIC MAINTENANCE

 

Periodic Maintenance Procedures

 

Fuel System (DFI)

 

Air Cleaner Element Cleaning

 

NOTE

○In dusty areas, the element should be cleaned more frequently than the recommended interval.

 

○After riding through rain or on muddily roads, the ele-ment should be cleaned immediately.

 

WARNING

 

If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possi-bly causing accident.

 

CAUTION

 

If dirt gets through into the engine, excessive en-gine wear and possibly engine damage will occur.

 

•Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter)

 

Air Switching Valve Hose [A] (Disconnect) Air Cleaner Element Screw [B]

Air Cleaner Element [C]

 

 

•Remove:

Upper Plastic Holder [A]

 

Element [B]

 

 

NOTE

○The wire screen [A] is fastened with an adhesive for the shaded portion [B]. Do not remove the wire screen.

 

PERIODIC MAINTENANCE 2-15

 

Periodic Maintenance Procedures

 

WARNING

Clean the element in a well -ventilated area, and make sure that there are no sparks or flame any-where near the working area.

 

Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element.

 

• Clean the element [A] in a bath of high-flash point solvent, and then dry it with compressed air or by shaking it.

• After cleaning, saturate a clean, lint-free towel with SE, SF, or SG class SAE 30 oil and apply the oil to the element by tapping the element outside with the towel.

 

• Visually check the element for tears or breaks.

• If_ment.the element has any tears or breaks, replace the ele-

 

• Install the element unit [A] with the foam element side (gray) [B] facing down.

 

Throttle Control System Inspection

 

• Check that the throttle grip moves smoothly from full open to close [A], and the throttle closes quickly and completely

 

by the return spring in all steering positions.

 

If the throttle grip doesn’t return properly, check the throt-tle cable routing, grip free play, and cable damage. Then lubricate the throttle cable.

 

•Check the throttle grip free play [A].

If the free play is incorrect, adjust the throttle cable.

 

Throttle Grip Free Play

 

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

 

PERIODIC MAINTENANCE