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General Specifications

Item Standard Limit
Model Code5LV5 (USA except for California) 
 5LV6 (CDN) 
 5LV7 (California) 
Dimensions  
Overall length2,125 mm (83.7 in) 
Overall width765 mm (30.1 in) 
Overall height1,190 mm (46.9 in) 
Seat height820 mm (32.3 in) 
Wheelbase1,450 mm (57.1 in) 
Minimum ground clearance140 mm (5.5 in) 
Minimum turning radius2,900 mm (114.2 in) 
Weight  
Wet (with oil and a full fuel tank)231 kg (509 lb) 
 232 kg (512 lb) (for california) 
Dry (without oil and fuel)208 kg (459 lb) 
 209 kg (461 lb) (for california) 
Maximum load (total of cargo, rider, passenger, and accessories)189 kg (417 lb) 
 188 kg (415 lb) (for california) 

Engine Specifications

Item Standard Limit
Engine  
Engine typeLiquid-cooled, 4-stroke, DOHC 
Displacement998 cm 3 
Cylinder arrangementForward-inclined parallel 4-cylinder 
Bore & stroke74 x 58 mm (2.91 x 2.28 in) 
Compression ratio11.4 : 1 
Engine idling speed1,050 - 1,150 r/min 
Vacuum pressure at engine idling speed30 kPa (225 mmHg, 8.86 in Hg) 
Standard compression pressure (at sea level)1,450 kPa (14.5 kg/cm2 , 206 psi) at 400 r/min 
Fuel  
Recommended fuelUnleaded fuel (for USA) 
 Regular unleaded gasoline (for CDN) 
Fuel tank capacity:  
Total (including reserve)21 L (18.5 Imp qt, 22.2 US qt) 
Reserve only4.0 L (3.52 Imp qt, 4.22 US qt) 
Engine Oil  
Lubrication systemWet sump 
Recommended oil:Yamalube 4 (20W40) or SAE 20W40 type SE motor oil 
Quantity:  
Total amount3.7 L (3.2 Imp qt, 3.8 US qt) 
Without oil filter cartridge replacement2.8 L (2.4 Imp qt, 2.9 US qt) 
With oil filter cartridge replacement3.0 L (2.6 Imp qt, 3.1 US qt) 
Oil pressure (hot)45 kPa (0.45 kg/cm2 , 6.40 psi) at 1,100 r/min 
Relief valve opening pressure490 - 570 kPa (4.9 - 5.7 kg/cm2 , 69.7 - 81.1 psi) 
Oil filter  
Oil filter typeCartridge (paper) 
Part number5GH-13440-00-00 
Oil Pump  
Oil pump typeTrochoidal 
Inner-rotor-to-outer-rotor-tip clearance0.09 - 0.15 mm (0.004 - 0.006 in) 
Outer-rotor-to-oil-pump-housing clearance0.03 - 0.08 mm (0.001 - 0.003 in) 
Bypass valve opening pressure180 - 220 kPa (1.8 - 2.2 kg/cm2 , 25.6 - 31.3 psi) 
Relief valve operating pressure490 - 570 kPa (71.1 - 82.7 psi) 
Oil pressure (hot)45 kPa @ 1100 rpm (6.5 psi @ 1100 rpm) 
Cooling System  
Radiator capacity2.4 L (2.11 Imp qt, 2.53 US qt) 
Radiator cap opening pressure95 - 125 kPa (0.95 - 1.25 kg/cm2 , 13.1 - 17.8 psi) 
Radiator core  
Width340 mm (13.4 in) 
Height238 mm (9.4 in) 
Depth24 mm (0.94 in) 
Coolant reservoir capacity0.3 L (0.26 Imp qt, 0.32 US qt) 
Water pump:  
Water pump typeSingle-suction centrifugal pump 
Reduction ratio68/43 x 28/28 (1.581) 
Max. impeller shaft tilt 0.15 mm (0.006 in)
Starting system type Electric starter 
Spark plugs  
Model (manufacturer) x quantityCR9E / U27ESR-N (NGK / DENSO) x 4 
Spark plug gap0.7 - 0.8 mm (0.028 - 0.031 in) 
Cylinder head  
Volume13.45 - 14.05 cc (0.82 - 0.86 in3) 
Max. warpage: 0.1 mm (0.004 in)
Camshafts  
Drive systemChain drive (right) 
Camshaft cap inside diameter24.500 - 24.521 mm (0.9646 - 0.9654 in) 
Camshaft journal diameter24.459 - 24.472 mm (0.9630 - 0.9635 in) 
Camshaft-journal-to-camshaft-cap clearance0.028 - 0.062 mm (0.0011 - 0.0024 in) 
Intake camshaft lobe dimensions:  
Measurement A32.5 - 32.6 mm (1.2795 - 1.2835 in)32.4 mm (1.2756 in)
Measurement B24.95 - 25.05 mm (0.9823 - 0.9862 in)24.85 mm (0.9783 in)
Measurement C7.45 - 7.65 mm (0.2933 - 0.3012 in) 
Exhaust camshaft lobe dimensions:  
Measurement A32.95 - 33.05 mm (1.2972 - 1.3012 in)32.85 mm (1.2933 in)
Measurement B24.95 - 25.05 mm (0.9823 - 0.9862 in)24.85 mm (0.9783 in)
Measurement C7.75 - 7.95 mm (0.3051 - 0.3126 in) 
Max. camshaft runout: 0.03 mm (0.0012 in)
Valve Timing  
Intake-open (BTDC)32° 
Intake-closed (ABDC)56° 
Exhaust-open (BBDC)61° 
Exhaust-closed (ATDC)35° 
Overlap angle67° 
Timing chain  
Model / number of linksRH2015 / 130 
Tensioning systemAutomatic 
Valves, valve seats, valve guides  
Valve clearance (cold)0.11 - 0.20 mm (0.0043 - 0.0079 in) 
Intake0.21 - 0 25 mm (0 0083 - 0 0098 in) 
Exhaust Valve Dimensions:
Head Diameter
Face Width
Seat Width
Margin Thickness
  
Valve head diameter A:  
Intake22.9 - 23.1 mm (0.9016 - 0.9094 in) 
Exhaust24.4 - 24.6 mm (0.9606 - 0.9685 in) 
Valve face width B:  
Intake1.76 - 2.90 mm (0.0693 - 0.1142 in) 
Exhaust1.76 - 2.90 mm (0.0693 - 0.1142 in) 
Valve seat width C:  
Intake0.9 - 1.1 mm (0.035 - 0.043 in) 
Exhaust0.9 - 1.1 mm (0.035 - 0.043 in) 
Valve margin thickness D:  
Intake0.5 - 0.9 mm (0.020 - 0.035 in) 
Exhaust0.5 - 0.9 mm (0.020 - 0.035 in) 
Valve stem diameter:  
Intake3.975 - 3.900 mm (0.1565 - 0.1535 in)3.945 mm (0.1553 in)
Exhaust4.465 - 4.480 mm (0.1758 - 0.1764 in)4.43 mm (0.1744 in)
Valve guide inside diameter:  
Intake4.000 - 4.012 mm (0.1575 - 0.1580 in)4.05 mm (0.1594 in)
Exhaust4.500 - 4.512 mm (0.1772 - 0.1776 in)4.55 mm (0.1791 in)
Valve-stem-to-valve-guide clearance:  
Intake0.010 - 0.037 mm (0.0004 - 0.0015 in)0.08 mm (0.0031 in)
Exhaust0.020 - 0.047 mm (0.0008 - 0.0019 in)0.10 mm (0.0039 in)
Valve stem runout: 0.01 mm (0.0004 in)
Valve seat width:  
Intake0.9 - 1.1 mm (0.035 - 0.043 in) 
Exhaust0.9 - 1.1 mm (0.035 - 0.043 in) 
Valve seat material - intakePB6 
Valve seat material - exhaustPB7W 
Valve springs free length:  
Intake38.90 mm (1.53 in) 
Exhaust40.67 mm (1.60 in) 
Spring rate - intake (K1)20.3 N/mm (115.91 lb/in) 
Spring rate - intake (K2)26.75 N/mm (152.74 lb/in) 
Spring rate - exhaust (K1)20.74 N/mm (118.43 lb/in) 
Spring rate - exhaust (K2)27.83 N/mm (158.91 lb/in) 
Installed length (valve closed):  
Intake34.50 mm (1.36 in) 
Exhaust35.00 mm (1.38 in) 
Compressed spring force (installed):  
Intake82 - 96 N (8.2 - 9.6 kg, 18.4 - 25.4 lb) 
Exhaust110 - 126 N (11.0 - 12.6 kg, 24.7 - 28.3 lb) 
Spring tilt:  
Intake 2.5° / 1.7 mm (2.5° / 0.067 in)
Exhaust 2.5° / 1.8 mm (2.5° / 0.071 in)
Winding direction (top view):  
IntakeClockwise 
ExhaustClockwise 
Cylinders  
Cylinder arrangementForward-inclined, parallel 4-cylinder 
Bore & stroke74 x 58 mm (2.91 x 2.28 in) 
Compression ratio11.4 : 1 
Bore74.00 - 74.01 mm (2.9134 - 2.9138 in) 
Max. taper 0.05 mm (0.0016 in)
Max. out-of-round 0.05 mm (0.0016 in)
Pistons  
Piston part number4XV-11631-00 
Piston-to-cylinder clearance0.030 - 0.055 mm (0.001 - 0.002 in)0.12 mm (0.005 in)
Diameter D:73.955 - 73.970 mm (2.9118 - 2.9122 in) 
Height H5 mm (0.20 in) 
Piston pin bore (in the piston):  
Diameter17.002 - 17.013 mm (0.6694 - 0.6698 in)17.043 mm (0.6710 in)
Offset0.5 mm (0.0197 in) 
Offset directionIntake side 
Piston pins:  
Outside diameter16.991 - 17.000 mm (0.6689 - 0.6693 in)16.971 mm (0.6681 in)
Piston-pin-to-piston-pin-bore clearance0.002 - 0.022 mm (0.00008 - 0.00087 in)0.072 mm (0.0028 in)
Piston rings:  
top ring -  
Ring typeBarrel 
Dimensions (B x T)0.90 x 2.75 mm (0.035 x 0.108 in) 
End gap (installed)0.32 - 0.44 mm (0.010 - 0.020 in) 
Ring side clearance0.030 - 0.065 mm (0.0012 - 0.0026 in) 
Plating/coatingChrome plated/ferox coating 
2nd ring -  
Ring typeTaper 
Dimensions (B x T)0.8 x 2.8 mm (0.031 x 0.110 in) 
End gap (installed)0.43 - 0.58 mm (0.017 - 0.023 in) 
Ring side clearance0.020 - 0.055 mm (0.0008 - 0.0022 in) 
Plating/coatingParkerrizing 
Oil ring -  
Dimensions (B x T)1.5 x 2.6 mm (0.059 x 0.101 in) 
End gap (installed)0.10 - 0.35 mm (0.004 - 0.014 in) 
Plating/coatingChrome plated/parkerrizing 
Connecting rods  
Crankshaft-pin-to-big-end-bearing clearance0.031 - 0.055 mm (0.0012 - 0.0022 in) 
Bearing color code1 = Violet 0 = White 1 = Blue 2 = Black 
Connecting rod length110.45 - 110.55 mm (4.348 - 4.352 in) 
Crankshaft  
Width A52.40 - 57.25 mm (2.063 - 2.254 in) 
Width B300.75 - 302.65 mm (11.84 - 11.92 in) 
Max. runout C 0.03 mm (0.0012 in)
Big end side clearance D0.160 - 0.262 mm (0.006 - 0.010 in) 
Crankshaft-journal-to-crankshaft-journal-bearing clearance0.029 - 0.053 mm (0.0011 - 0.0021 in) 
Bearing color code1 = Pink/violet 0 = Pink/white 1 = Pink/blue 2 = Pink/black 3 = Pink/brown 
Position of thrust bearing#4 Journal 
Clutch  
Clutch typeWet, multiple disc 
Clutch release methodCam (pull rod type) 
Clutch release method operationCable operation 
OperationLeft-hand operation 
Clutch cable free play (at the end of the clutch lever)10 - 15 mm (0.39 - 0.59 in) 
Friction plates:  
Thickness2.92 - 3.08 mm (0.115 - 0.121 in)2.82 mm (0.111 in)
Plate quantity8 
Thickness3.42 - 3.58 mm (0.135 - 0.141 in)3.32 mm (0.131 in)
Plate quantity1 
Clutch plates:  
Thickness1.9 - 2.1 mm (0.075 - 0.083 in) 
Plate quantity8 
Max. warpage 0.1 mm (0.004 in)
Clutch springs:  
Free length50 mm (1.97 in) 
Spring quantity6 
Transmission  
Transmission typeConstant mesh, 6-speed 
Primary reduction systemSpur gear 
Primary reduction ratio68/43 (1.581) 
Secondary reduction systemChain drive 
Secondary reduction ratio44/16 (2.750) 
OperationLeft-foot operation 
Gear ratios:  
1st gear35/14 (2.500) 
2nd gear35/19 (1.842) 
3rd gear30/20 (1.500) 
4th gear28/21 (1.333) 
5th gear30/25 (1.200) 
6th gear29/26 (1.115) 
Max. main axle runout 0.08 mm (0.003 in)
Max. drive axle runout 0.08 mm (0.003 in)
Shifting mechanism  
Shift mechanism typeGuide bar 
Max. shift fork guide bar bending 0.1 mm (0.004 in)
Installed shift rod length260 mm (10.2 in) 
Air filter type Dry element 
Fuel pump  
Pump typeElectrical 
Model (manufacturer)4SV (MITSUBISHI) 
Output pressure20 kPa (0.2 kg/cm2, 2.8 psi) 
Carburetors  
Model (manufacturer) x quantityBSR37 (MIKUNI) x 4 
Throttle cable free play (at the flange of the throttle grip)3 - 5 mm (0.12 - 0.20 in) 
ID mark5LV5 40 
Main jetCarburetors 1 and 4: #132.5 
 Carburetors 2 and 3: #130 
Main air jet#80 
Jet needleCarburetor 1 and 4: 5D129-3/5 
 Carburetor 2 and 3: 5D130-3/5 
Needle jetP-OM 
Pilot air jet#85 
Pilot outlet1.0 
Pilot jet#15 
Bypass 10.9 
Bypass 20.9 
Bypass 30.9 
Pilot screw turns out2.0 
Valve seat size1.5 
Starter jet 1#42.5 
Starter jet 20.8 
Throttle valve size#115 
Fuel level (above the line on the float chamber)3.0 - 4.0 mm (0.118 - 0.157 in) 
Idling Condition  
Engine idle speed1050 - 1150 rpm 
CO% with AIS blocked4 - 5% 
Intake vacuum225 mm Hg (8.858 in Hg) 
Water temperature95 - 105°C 
oil temperature85 - 95°C 
Max. EXUP cable free play (at the EXUP valve pulley)1.5 mm (0.059 in) 

Chassis Specifications

Item Standard Limit
Frame  
Frame typeDouble cradle 
Caster angle26° 
Trail104 mm (4.09 in) 
Front wheel  
Wheel typeCast wheel 
Rim:  
Size17 x MT3.50 
MaterialAluminum 
Wheel travel140 mm (5.51 in) 
Wheel runout:  
Max. radial wheel runout 1 mm (0.04 in)
Max. lateral wheel runout 0.5 mm (0.02 in)
Rear wheel  
Wheel typeCast wheel 
Rim:  
Size17 x MT5.50 
MaterialAluminum 
Wheel travel135 mm (5.31 in) 
Wheel runout:  
Max. radial wheel runout 1 mm (0.04 in)
Max. lateral wheel runout 0.5 mm (0.02 in)
Front tire  
Tire typeTubeless 
Size120/70 ZR17 (58W) 
Model (manufacturer)MEZ4Y FRONT (METZELER) 
 BT020F U (BRIDGESTONE) 
Tire pressure (cold):  
0 - 90 kg250 kPa (2.5 kgf/cm2, 36 psi) 
90 - 201 kg250 kPa (2.5 kgf/cm2, 36 psi) 
High-speed riding250 kPa (2.5 kgf/cm2, 36 psi) 
Min. tire tread depth 1.0 mm (0.04 in)
Rear tire  
Tire typeTubeless 
Size180/55 ZR17 (73W) 
Model (manufacturer)MEZ4Y (METZELER) 
 BT020R U (BRIDGESTONE) 
Tire pressure (cold):  
0 - 90 kg270 kPa (2.7 kgf/cm2, 39 bar) 
90 - 201 kg290 kPa (2.9 kgf/cm2, 42 bar) 
High-speed riding290 kPa (2.9 kgf/cm2, 42 bar) 
Min. tire tread depth1.0 mm (0.04 in) 
Front brakes  
Brake typeDual-disc brake 
OperationRight-hand-operation 
Brake lever free play2.3 - 11.5 mm (0.09 - 0.45 in) 
Recommended fluidDOT 4 
Brake discs:  
Diameter x thickness298 x 5 mm (11.7 x 0.20 in) 
Min. thickness 4.5 mm (0.18 in)
Max. deflection 0.1 mm (0.004 in)
Brake pad lining thickness:5.5 mm (0.22 in)0.5 mm (0.02 in)
Master cylinder inside diameter14 mm (0.05 in) 
Caliper cylinder inside diameter30.2 mm (1.19 in) and 27 mm (1.06 in) 
Rear brake  
Brake typeSingle-disc brake 
OperationRight-foot operation 
Brake pedal position (from the top of the brake pedal to the top of the rider footrest)35 - 40 mm (1.38 - 1.57 in) 
Brake pedal free play4.0 - 8.5 mm (0.16 - 0.33 in) 
Recommended fluidDOT 4 
Brake discs:  
Diameter x thickness267 x 5 mm (10.51 x 0.20 in) 
Min. thickness 4.5 mm (0.18 in)
Max. deflection 0.1 mm (0.004 in)
Brake pad lining thickness:5.5 mm (0.22 in)0.5 mm (0.02 in)
Master cylinder inside diameter12.7 mm (0.5 in) 
Caliper cylinder inside diameter42.9 mm (1.69 in) 
Front suspension  
Suspension typeTelescopic fork 
Front fork typeCoil spring/oil damper 
Front fork travel140 mm (5.51 in) 
Spring:  
Free length344.0 mm (13.5 in) 
Spacer length66.0 mm (2.60 in) 
Installed length320.0 mm (12.6 in) 
Spring rate (K1)7.8 N/mm (0.78 kg/mm, 43.7 lb/in) 
Spring rate (K2)11.8 N/mm (1.2 kg/mm, 67.2 lb/in) 
Spring stroke (K1)0 - 64 mm (0 - 2.52 in) 
Spring stroke (K2)64 - 140 mm (2.52 - 5.51 in) 
Optional spring availableNo 
Fork oil:  
Recommended oilSuspension oil 01 or equivalent 
Quantity (each front fork leg)435 cm 3 (15.3 Imp oz, 14.7 US oz) 
Level (from the top of the inner tube, with the inner tube fully compressed, and without the fork spring)140 mm (5.51 in) 
Spring preload adjusting positions:  
Minimum5 (from fully turned out position) 
Standard2 
Maximum1 
Rebound damping adjusting positions:  
Minimum17 (from fully turned-in position) 
Standard7 
Maximum1 
Compression damping adjusting positions:  
Minimum21 (from fully turned-in position) 
Standard6 
Maximum1 
Steering  
Steering bearing typeAngular ball bearings 
Lock to lock angle (left)34° 
Lock to lock angle (right)34° 
Rear suspension  
Suspension typeSwingarm (link suspension) 
Rear shock absorber assembly typeCoil spring/gas-oil damper 
Rear shock absorber assembly travel65 mm (2.56 in) 
Spring:  
Free length182.5 mm (7.19 in) 
Installed length163 mm (6.42 in) 
Spring rate (K1)73.6 N/mm (7.5 kg/mm, 420 lb/in) 
Spring stroke (K1)0 - 65 mm (0 - 2.56 in) 
Optional spring availableNo 
Standard spring preload gas/air pressure1,200 kPa (12 kg/cm2, 170.7 psi) 
Spring preload adjusting positions:  
Minimum1 (from fully turned-in position) 
Standard6 
Maximum11 
Rebound damping adjusting positions:  
Minimum20 (from fully turned-in position) 
Standard10 
Maximum3 
Compression damping adjusting positions:  
Minimum1 (from fully turned-in position) 
Standard7 
Maximum12 
Swingarm  
Free play (at the end of the swingarm):  
Radial 1 mm (0.04 in)
Axial 1 mm (0.04 in)
Drive chain  
Model (manufacturer)50ZVM (DAIDO) 
Link quantity116 
Drive chain slack40 - 50 mm (1.57 - 1.97 in) 
Maximum ten-link section150.1 mm (5.91 in)152.5 mm (6.00 in)

Electrical Specifications

Item Standard Limit
System voltage12 V 
Ignition system  
Ignition system typeTransistorized coil ignition 
Ignition timing5° BTDC at 1,100 r/min 
Advanced timing55° BTDC at 5,000 r/min 
Advancer typeThrottle position sensor and electrical 
Pickup coil resistance/color248 - 372 ohms/Gy-B 
Transistorized coil ignition unit model (manufacturer)TNDF69 (DENSO) 
Ignition coils  
Model (manufacturer)J0313 (DENSO) 
Minimum ignition spark gap6 mm (0.24 in) 
Primary coil resistance1.87 - 2.53 ohms 
Secondary coil resistance12 - 18 k ohms 
Spark plug caps  
MaterialRubber 
Resistance10 k ohms 
Throttle position sensor standard resistance4 - 6 k ohms 
Charging system  
System typeAC magneto 
Model (manufacturer)F4T361 (MITSUBISHI) 
Normal output14 V / 365 W at 5,000 r/min 
Stator coil resistance/color0.27 - 0.33 ohms at 20°C (68°F)/W-W 
Rectifier/regulator  
Regulator typeSemiconductor short circuit 
Model (manufacturer)SH650C-11 (SHINDENGEN) 
No-load regulated voltage14.1 - 14.9 V 
Rectifier capacity18 A 
Withstand voltage200 V 
Battery  
Battery typeGT14B-4 
Battery voltage/capacity12 V / 12 AH 
Specific gravity1.320 
Headlight typeHalogen bulb 
Bulbs (voltage/wattage x quantity)  
Headlight12 V 60 W / 55 W x 2 
Auxiliary light12 V 5 W x 2 
Tail/brake light12 V 5 W / 21 W x 2 
Front turn signal light12 V 8 W / 27 W x 2 
Rear turn signal light12 V 27 W x 2 
Meter light12 V 2 W x 3 
Indicator light (voltage/wattage x quantity)  
Neutral indicator light14 V 1.4 W x 1 
High beam indicator light14 V 1.4 W x 1 
Oil level indicator light14 V 1.4 W x 1 
Turn signal indicator light14 V 1.4 W x 2 
Fuel indicator light12 V 2 W x 1 
Water temperature indicator lightLED 
Electric starting system  
System typeConstant mesh 
Starter motor:  
Model (manufacturer)SM-13 (MITSUBA) 
Power output0.8 kW 
Brushes:  
Overall length12.5 mm (0.49 in)4 mm (0.16 in)
Spring force7.65 - 10.01 N (780 - 1,021 gf, 27.5 - 36.0 oz) 
Commutator resistance0.025 - 0.035 ohms 
Commutator diameter28 mm (1.10 in)27 mm (1.06 in)
Mica undercut0.7 mm (0.03 in) 
Starter relay  
Model (manufacturer)MS5F-631 (JIDECO) 
Amperage180 A 
Coil resistance4.18 - 4.62 ohms 
Starting circuit cutoff relay  
Model (manufacturer)G8R-30YM (Omron) 
Coil resistance180 ohms +/- 10% 
Headlight relay  
Model (manufacturer)G8H-1C4T-D-ST6-Y48 (Omron) 
Coil resistance80 ohms +/- 10% 
Fuel pump relay  
Coil resistance180 ohms +/- 10% 
Horn  
Horn typePlain 
Model (manufacturer) x quantityYF-12 (NIKKO) x 1 
Max. amperage3 A 
Turn signal relay  
Relay typeFull-transistor 
Model (manufacturer)FE246BH (DENSO) 
Self-cancelling device built-inNo 
Turn signal blinking frequency75 - 95 cycles/min. 
Wattage27 W x 2 + 3.4 W 
Oil level switch  
Model (manufacturer)5LV (DENSO) 
Fuel sender  
Model (manufacturer)5LV (NIPPON SEIKI) 
Resistance4 - 100 ohms at 25°C (77°F) 
Sidestand/fuel pump relay  
Model (manufacturer)5EB-20 (OMRON) 
Coil resistance180 ohms 
Fuel pump maximum amperage1.2 A 
Radiator fan  
Model (manufacturer)4XV (TOYO RADIATOR) 
Thermo switch  
Model (manufacturer)5JJ (NIPPON THERMOSTAT) 
Fuses (amperage x quantity)  
Main fuse30 A x 1 
Headlight fuse20 A x 1 
Signaling system fuse20 A x 1 
Ignition fuse20 A x 1 
Radiator fan fuse10 A x 1 
Turn signal relay fuse10 A x 1 
Backup fuse (odometer)10 A x 1 
Reserve fuse30 A x 1 
 20 A x 1 
 10 A x 1 

Engine Tightening Torques

  Tightening Torque
Item Fastener Thread Size Q'ty Nm m-Kg lb-ft
Spark plugs M104131.39.4
Cylinder headNutM108505.036
Cylinder headCap nutM102505.036
Cylinder headBoltM62121.28.7
Camshaft capsBoltM628101.07.2
Cylinder head coverBoltM66121.28.7
Cylinder head (exhaust pipe)Stud BoltM88151.511
Connecting rod capsNutM88363.625
Generator rotorBoltM10165 + 60°6.5 + 60°47 + 60°
Crankshaft sprocketBoltM101606.043
Cap Bolt (timing chain tensioner)BoltM616.40.644.6
Camshaft sprocketBoltM74242.417
Water pump inlet pipeBoltM61101.07.2
Water pump outlet pipeBoltM61101.07.2
Oil/water pump assembly driven sprocketBoltM61151.511
Oil pumpBoltM61121.28.7
Oil coolerBoltM201353.525
Engine oil drain BoltBoltM141434.331
Oil strainer housingBoltM62101.07.2
Oil/water pump assembly driven sprocket coverBoltM61121.28.7
Oil delivery pipeBoltM61101.07.2
Oil filter BoltBoltM201707.051
Oil filter cartridge M201171.712
Oil pipeBoltM62101.07.2
Oil strainer coverBoltM62101.07.2
Air cleaner cap and air cleanerScrewM6460.64.3
Frame and air cleanerBoltM6370.75.1
Air cleaner cover and air cleanerScrewM6620.21.4
Ring nut and cylinder headNutM88202.014
Exhaust pipe and mufflerBoltM83202.014
Emission check BoltBoltM84101.07.2
EXUP pulley coverBoltM63101.07.2
EXUP cable bracketBoltM63101.07.2
EXUP pulley and shaft armBoltM51101.07.2
Exhaust jointBoltM4230.32.2
Exhaust pipe assemblyBoltM81202.014
Air induction system pipeBand 43.50.352.5
Crankcase (cylinder head)Stud BoltM1010101.07.2
CrankcaseBoltM910See NoteSee NoteSee Note
CrankcaseBoltM62141.410
CrankcaseBoltM614121.28.7
CrankcaseBoltM82242.417
AC magneto coverBoltM69121.28.7
Drive sprocker coverBoltM64101.07.2
PlateBoltM62101.07.2
Clutch coverBoltM68121.28.7
Timing chain cap BoltBoltM68121.28.7
Shift shaft coverBoltM65121.28.7
Breather plateBoltM65101.07.2
Timing mark accessing screwBoltM81151.511
Starter clutch idle gear shaftBoltM61101.07.2
Starter one-way clutchBoltM63121.28.7
Clutch boss (use lock washer)NutM201909.065
Clutch springBoltM6680.85.8
Drive sprocket (use lock washer)NutM221858.561
Main axle bearing housingScrewM63121.28.7
Shift lever stopperBoltM62101.07.2
Stopper screwScrewM81222.216
Shift rod (left thread)NutM616.50.654.7
Shift rodNutM626.50.654.7
Shift rod jointBoltM61101.07.2
Shift armBoltM61101.07.2
AC magneto stator coilScrewM63141.410
Ignitor unitScrewM5271.07.2
Neutral switch M101202.014
Pick up coilBoltM62101.07.2
Thermo unit NPT 1/8"1151.511
Note:
1. First, tighten the bolt to approximately 14.7 Nm (1.5 m-Kg, 11 lb-ft) with a torque wrench
2. Tighten another 45 - 50°

Chassis Tightening Torques

  Tightening Torque
Item Thread Size Nm m-Kg lb-ft
Upper bracket pinch boltM8303.022
Upper bracket cap nutM221101180
Upper bracket and handlebar holderM10323.223
Handlebar holderM8232.317
Lower bracket pinch bolt 232.317
Lower bracket ring nut (See Note)M25181.813
Front brake master cylinderM6101.07.2
Front brake hose union boltM10303.022
Engine Mounting:    
Engine mounting bolt/nutM10555.540
Engine mounting bolt/nutM8333.324
Frame and down tubeM10898.964
Clutch cable lock nutM870.75.1
Ignition coil and stayM670.75.1
Pivot shaftM1812512.590
Rear shock absorber (upper)M10404.029
Rear shock absorber and relay armM10404.029
Relay arm and frameM10404.029
Relay arm and connecting armM12484.835
Connecting arm and swing armM12484.835
Drive chain guardM670.75.1
Drive chain caseM670.75.1
Fuel cockM670.75.1
Fuel senderM540.42.9
Side coverM640.42.9
Coolant reservoir tankM640.42.9
Front wheel axleM16727.252
Front wheel axle pinch boltM8232.317
Front brake caliperM10404.029
Front brake diskM6181.813
Front brake bleed screwM860.64.3
Rear brake torque rodM8232.317
Rear wheel sprocketM10696.950
Drive chain adjusting nutM8161.612
Rear brake caliperM10404.029
Rear wheel axleM2415015108
Rear brake hose union boltM10303.022
Rear brake bleed screwM860.64.3
Rear brake diskM8232.317
Rider footrest bracket and frameM8303.022
Rear brake reservoir tankM640.42.9
Rear brake master cylinderM8232.317
Rider footrest and bracketM10555.540
Passenger footrest bracket and frameM8282.820
Passenger footrest bracket and mufflerM10484.835
Note:
1. First, tighten the ring nut to approximately 52 Nm (5.2 m-Kg, 38 lb-ft) with a torque wrench
2. Loosen the ring nut completely
3. Retighten the ring nut to specification