Item description | Thread Diameter | Torque | Remarks | |
( MM ) | ( FT-LB ) | |||
Lubrication: | ||||
Oil pump driven sprocket bolt | 6 | 11 | Note 1 | |
Oil pressure switch | PT 1/8 | 9 | Note 3 | |
Oil filter | 20 | 7 | Note 5 | |
Oil drain bolt | 12 | 27 | ||
Oil cooler bolt ('91-'95) | 20 | 47 | ||
Oil filter boss | 20 | 20 | Note 1 | |
Oil pan bolt | 6 | 9 | ||
Timing belt\cylinder head: | ||||
Timing belt tensioner bolt | 10 | 33 | ||
Timing belt idler pulley bolt | 12 | 33 | Note 1 | |
Timing belt driven pulley bolt | 8 | 20 | ||
Timing belt drive pulley bolt | 12 | 47 | ||
Cylinder head bolt | 10 | 42 | Note 2 | |
Camshaft holder bolt | 6 | 9 | ||
Cylinder head cover bolt | 6 | 9 | ||
Spark plug | 10 | 8 | ||
Vacuum joint | 5 | 2.9 | ||
Reduction bolt | 12 | 27 | ||
Clutch\gearshift linkage: | ||||
Clutch lock nut | 22 | 80 | ||
Shift drum center bolt | 8 | 17 | ||
Shift return spring pin bolt | 8 | 17 | ||
Slave cylinder bleed valve | 8 | 6.5 | ||
Gearshift arm bolt | 6 | 9 | ||
Crankshaft\crankshaft\transmission: | ||||
Connecting rod cap nut | 8 | 26 | Note 2 | |
Crankcase bolt - 6 mm | 6 | 9 | ||
8 mm | 8 | 17 | Note 2 | |
10 mm | 10 | 38 | Note 2 | |
Pulse generator rotor bolt | 12 | 72 | Note 2 | |
Neutral switch | 10 | 9 | ||
32 mm cap | 32 | 9 | Note 5 | |
Alternator: | ||||
Alternator terminal nut (after '95) | 6 | 5.8 | ||
Alternator shaft nut | 14 | 42 | Note 1 | |
Alternator drive gear bolt | 6 | 12 | Note 1 | |
Frame\body panels: | ||||
Center stand pivot bolt | 8 | 20 | ||
Side stand pivot bolt | 10 | 7 | ||
Side stand pivot lock nut | 10 | 20 | ||
Rotary switch attaching bolt | 6 | 7 | ||
Footpeg holder - 8 mm | 8 | 20 | ||
- 10 mm | 10 | 25 | ||
Grab rail | 8 | 20 | ||
Grab rail center plate bolt | 8 | 25 | ||
Saddle bag stay bolt - 6 mm | 6 | 7 | ||
- 8 mm | 8 | 25 | ||
Center stand grip bolt | 6 | 7 | ||
Engine guard mounting bolt | 8 | 20 | ||
Windshield screw | 5 | .43 | ||
Upper fairing bracket bolt | 8 | 20 | ||
Exhaust system: | ||||
Exhaust pipe joint nut | 7 | 12 | ||
Muffler band bolt | 8 | 16 | ||
Exhaust pipe band bolt | 8 | 16 | ||
Muffler mounting bolt | 8 | 20 | ||
Exhaust pipe protector bolt | 6 | 9 | ||
Fuel system: | ||||
Fuel tank mounting bolt | 6 | 9 | ||
Fuel pump mounting nut | 6 | 7 | ||
Carburetor connecting screw | 6 | 5.8 | ||
Air cleaner housing cover screw | 5 | 0.65 | ||
Fuel valve mounting screw | 5 | 0.65 | ||
Cooling system: | ||||
Fan motor switch | 16 | 9 | ||
Thermostat case | 6 | 7 | ||
Water hose band screw | -- | 0.9 | ||
Engine mount: | ||||
Engine mounting bolt - 10 mm | 10 | 40 | Note 2 | |
- 12 mm | 12 | 47 | ||
Engine mounting bracket bolt - 8 mm | 8 | 25 | ||
- 10 mm | 10 | 29 | ||
Sub frame bolt | 10 | 29 | ||
Engine mounting collar lock nut ('91-'95) | 18 | 15 | ||
(after '95) | 18 | 20 | ||
Engine mounting collar adjusting nut (lower) | ||||
(after '95) | 18 | 7 | ||
Gearshift pedal pivot bolt | 8 | 20 | Note 1 |
Notes: | 1. | Apply locking agent to threads. |
2. | Apply oil to threads and flange surface. | |
3. | Apply sealant to threads. | |
4. | Stake. | |
5. | Apply clean engine oil to o-ring. |
Item description | Thread Diameter | Torque | Remarks | |
( MM ) | ( FT-LB ) | |||
Front suspension: | ||||
Handlebar lower cover bolt | 5 | 3.1 | ||
Handlebar upper holder bolt | 8 | 20 | ||
Handlebar weight screw | 6 | 6.5 | Note 1 | |
Ignition switch mounting bolt | 8 | 18 | ||
Throttle housing screw | 5 | 3.0 | ||
Front fender attaching socket bolt | ||||
Standard and LBS-ABS\TCS model | 6 | 9 | ||
ABS\TCS model | 8 | 16 | ||
Front fender plate bolt (LBS-ABS\TCS model) | 8 | 16 | Front side bolts | |
Steering bearing adjustment nut | 26 | 20 | Note 2 | |
Steering stem nut | 24 | 76 | ||
Upper fork pinch | 8 | 17 | ||
Lower fork pinch bolt | 10 | 36 | ||
Fork cap | ||||
Standard and LBS-ABS\TCS model | --- | 14 | ||
LBS-ABS\TCS model | --- | 17 | ||
Fork socket bolt | 8 | 14 | Note 1 | |
Fork damper lock nut | 10 | 17 | ||
Anti-dive case bolt | 5 | 2.9 | Note 1 | |
Front axle bolt | 14 | 65 | ||
Front axle pinch bolt | 8 | 16 | ||
Front pulser ring bolt (ABS\TCS or LBS-ABS\TCS model) | 5 | 5.8 | ||
Rear suspension: | ||||
Shock absorber upper mounting bolt | 10 | 36 | Note 2 | |
Shock absorber lower mounting bolt | 8 | 17 | ||
Swingarm right pivot bolt | 30 | 76 | ||
Swingarm left pivot bolt | ||||
Standard and ABS\TCS model | 30 | 13 | ||
LBS-ABS\TCS model | 30 | 16 | ||
Swingarm left pivot bolt lock nut | 30 | 76 | ||
Rear axle nut | 18 | 80 | ||
Rear axle pinch bolt | 8 | 20 | ||
Rear wheel dampner plate bolt | 6 | 14 | ||
Rear pulser ring bolt ( ABS\TCS or LBS-ABS\TCS models ) | 5 | 5.8 | ||
Brake\clutch system: | ||||
Front wheel speed sensor bracket bolt ( LBS-ABS\TCS model ) | 6 | 9 | ||
Rear caliper stopper pin bolt | 18 | 51 | ||
Pad pin plug | 10 | 1.8 | ||
Pad pin | 10 | 13 | ||
Caliper assembly bolt ( LBS-ABS\TCS model ) | 8 | 24 | ||
Front caliper pin bolt | ||||
( caliper side ) | 8 | 17 | Note 1 | |
( bracket side ) | 8 | 9 | Note 1 | |
Rear caliper pin bolt | ||||
( caliper side ) Standard and ABS\TCS model | 12 | 20 | Note 1 | |
LBS-ABS\TCS model | 12 | 20 | Note 1 | |
( bracket side ) Standard and ABS\TCS model | 8 | 17 | Note 1 | |
LBS-ABS\TCS model | 8 | 17 | Note 1 | |
Caliper bleed valvel | ||||
Standard and ABS\TCS model | --- | 4.0 | ||
LBS-ABS\TCS model | --- | 4.0 |
Notes: | 1. | Apply locking agent to threads. |
2. | Apply oil to threads and flange surface. | |
3. | Apply sealant to threads. | |
4. | Stake. | |
5. | Apply clean engine oil to o-ring. |
Item description | Thread Diameter | Torque | Remarks | |
( MM ) | ( FT-LB ) | |||
Brake\Clutch System (cont'd): | ||||
Right front caliper mounting bolt (Standard and ABS\TCS model) | 8 | 20 | ||
Left front caliper pivot bolt (Standard and ABS\TCS model): | ||||
upper | 8 | 20 | ||
lower | 6 | 9 | ||
Right front caliper pivot bolt (LBS-ABS\TCS model): | ||||
upper | 8 | 22 | ||
lower | 6 | 9 | ||
Left front caliper pivot bolt (LBS-ABS\TCS model) | 8 | 22 | ||
Brake disc bolt: | 8 | 31 | ||
Rear master cylinder push rod lock nut | 8 | 13 | ||
Secondary master cylinder mounting bolt (LBS-ABS\TCS model) | 6 | 9 | ||
Secondary master cylinder push rod lock nuts (LBS-ABS\TCS model) | 8 | 13 | Note 1 | |
Secondary master cylinder link plate bolt (LBS-ABS\TCS model) | 8 | 22 | ||
Delay valve mounting bolt (LBS-ABS\TCS model) | 6 | 9 | ||
Brake lever adjuster rod bolt | 5 | 29 | Note 1 | |
Master cylinder holder bolt | 6 | 9 | ||
Master cylinder reservoir cap screw | 4 | 1.1 | ||
Clutch lever pivot nut | 6 | 4.3 | ||
Clutch lever pivot bolt | 6 | 0.7 | ||
Clutch switch mounting screw | 4 | 0.9 | ||
Brake lever pivot nut | 6 | 4.3 | ||
Front brake lever pivot nut | 6 | 0.7 | ||
Front brake switch mounting screw | 4 | 0.9 | ||
Brake hose oil bolt | ||||
Standard model | 10 | 25 | ||
ABS\TCS model | 10 | 25 | ||
LBS-ABS\TCS model | 10 | 25 | ||
Clutch hose oil bolt | 10 | 25 | ||
Brake pipe joint nut (LBS-ABS\TCS model) | --- | 12 | ||
Brake hose clamp screw (at fork tube; Standard model) | 5 | 3.1 | ||
Final drive: | ||||
Final gear case mounting nut | 10 | 43 | ||
Final gear case oil filler cap | 30 | 9 | ||
Pinion bearing retainer | 70 | 108 | ||
Pinion joint nut | 16 | 80 | Note 1 | |
Retainer lock washer bolt | 6 | 7 | ||
Final gear case bolt | ||||
8 mm | 8 | 19 | ||
10 mm | 10 | 46 | Note 1 | |
Final gear case drain bolt | 14 | 14 | ||
Dust guard plate bolt | 6 | 7 | ||
Electrical system: | ||||
Ignition coil mounting bolt | 6 | 6.5 | ||
Meter mounting bolt | 6 | 6.5 |
Notes: | 1. | Apply locking agent to threads. |
2. | Apply oil to threads and flange surface. | |
3. | Apply sealant to threads. | |
4. | Stake. | |
5. | Apply clean engine oil to o-ring. |
Fastener Type | Torque | Fastener Type | Torque | |
( FT-LB ) | ( FT-LB ) | |||
5 mm bolt and nut | 3.5 | 5 mm screw | 3 | |
6 mm bolt and nut | 7.2 | 6 mm screw | 7 | |
8 mm bolt and nut | 16 | 6 mm flange bolt ( 8 mm head ) | 7 | |
10 mm bolt and nut | 25 | 6 mm flange bolt ( 10 mm head ) and nut | 9 | |
12 mm bolt and nut | 40 | 8 mm flange bolt and nut | 20 | |
10 mm flange bolt and nut | 29 |