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|
Система охлаждения
Пункт
| Стандарт
| Допуск
| Объем охл. жидкости (радиатор и двигатель)
(Резервный бачок)
Давление на крышке радиатора
Термостат начинает открываться при:
Термостат открыт полностью при:
Thermostat valve lift
| 2,6 литра
0,4 литра
108-137 kPa (16-20 psi)
80o-84oC
95oC
8.0 minimun
| -
-
-
-
-
-
| Голова блока цилиндров
Компрессия в цилиндрах
Разница в компрессии цилиндров при синхронизации
Клапанный зазор (впуск )IN
(выпуск) EX
Перекос головки блока цилиндров
Cam lobe height (1) IN (ED, E, G, ND, SP, IT, U type)
IN (F type)
IN (SW, AR type)
EX (ED, E, G, ND, SP, IT, U type)
EX (F type)
EX (SW, AR type)
Биение распредвала
Camshaft oil clearance A
B
Camshaft journal O.D A (Except F type)
A (F type)
B (Except F type)
B (F type)
Valve stem O.D IN
EX
Valve guide I.D. IN
EX
Stem-to-guide clearance IN
EX
Valve guide projection above cylinder head IN
EX
Before guide installation:
1. Chill the valve guides in the freezer section of the refrigerator for about an hour.
2. Heat the cylinder head to 100-150oC
Valve seat width
Valve spring free length inner IN
Inner EX
Outer IN
Outer EX
| 1,050-1,450 kpa (10.5-14.4 kg/cm2)/400 min-1 (rpm)
40 mm Hg
0.10 +/- 0.002 (0.004+/-0.001)
0.18+/-0.002 (0.007+/-0.001)
---
35.668-35.748
33.352-33.432
34.907-34.987
35.540-35.620
35.540-35.620
34.835-34.915
-
0.020-0.062
0.050-0.092
27.959-27.980
27.459-27.480
27.929-27.950
27.421-27.450
5.475-5.490
5.455-5.470
5.500-5.512
5.500-5.512
0.010-0.037
0.030-0.057
17.8-18.0
17.8-18.0
0.9-1.1
43.15
43.15
47.08
47.08
| -
-
-
-
-
0.07
35.62
33.30
34.85
35.49
35.49
34.79
0.03
0.12
0.14
-
-
-
-
5.47
5.45
5.55
5.55
-
-
-
-
1.5
41.8
41.8
45.7
45.7
| 1-7
Цилиндр и поршни
Наименование
| Стандарт
| Сервисный лимит
| Cylinder I.D.
Cylinder out of round
Cylinder taper
Cylinder warpage
Piston mark direction
Piston O.D. (D)
Piston O.D. measurement point (H)
Piston pin hole I.D. (d)
Cylinder-to-piston clearance
Piston pin O.D.
Piston-to-piston pin clearance
Connecting rod-to piston pin clearance
Top ring-to-ring groove clearance
Second ring-to-ring groove clearance
Top Ring end gap
Second Ring end gap
Oil ring (side rail) end gap
Top ring mark
Second ring mark
| 77.000-77.010 (3.0315-3.0319)
-
-
-
“IN” mark facing the intake side
76.970-76.990 (3.0303-3.0311)
15 mm (0.6 in) from the bottom
20.002-20.008 (0.7875-0.7877)
0.010-0.040 (0.0004-0.0016)
19.994-20.000 (0.7872-0.7874)
0.002-0.014 (0.0001-0.0006)
0.016-0.040 (0.0006-0.0016)
0.025-0.055 (0.0010-0.0022)
0.015-0.045 (0.0006-0.0018)
0.250-0.400 (0.0100-0.0157)
0.320-0.470 (0.0126-0.0185)
0.300-0.900 (0.0118-0.0354)
Marking side facing up
Marking side facing up
| 77.10 (3.305)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
-
76.87 (3.026)
-
20.06 (0.790)
0.10 (0.004)
19.98 (0.787)
0.04 (0.002)
0.06 (0.002)
0.09 (0.004)
0.10 (0.004)
0.58 (0.023)
0.65 (0.026)
1.10 (0.043)
-
-
| Система сцепления
Recommended clutch fluid
Clutch master cylinder I.D.
Clutch master piston O.D.
Clutch outer I.D.
Clutch outer guide I.D.
Mainshaft O.D. at clutch outer guide
Clutch spring free length
Clutch disc thickness A
B
Clutch plate warpage
| Тормозная жидкость DOT 4
14.000-14.043 (0.5512-0.5529)
13.957-13.984 (0.5495-0.5506)
47.005-47.030 (1.8506-1.8516)
27.995-28.012 (1.1022-1.1028)
27.980-27.993 (1.1016-1.1021)
46.7 (1.839)
3.42-3.58 (0.135-0.141)
3.72-3.33 (0.146-0.153)
---
| ---
16.06 (0.554)
13.94 (0.549)
47.10 (1.854)
28.08 (1.106)
27.97 (1.101)
44.7 (1.76)
3.1 (0.12)
3.1 (0.12)
0.30 (0.012)
|
1-8
Transmission
Наименование
| Стандарт
| Сервисный лимит
| Transmission gear I.D. M5, M6
C2, C3, C4
Transmission gear bushing O.D. M5, M6
C2, C3, C4
Transmission gear bushing I.D. M5
C2
Gear-to-bushing clearance at M5, M6 gear
At C2, C3, C4 gear
Mainshaft O.D. at M5 gear
Countershaft O.D. at C2 gear
Gear bushing-to shaft clearance at M5 gear
At C2 gear
Shift fork claw thinkness L
C
R
Shift fork I.D. L
C
R
Shift fork shaft O.D. L
C
R
| 31.000-31.016 (1.2205-1.2211)
33.000-33.016 (1.2992-1.2998)
30.955-30.980 (1.2187-1.2197)
32.955-32.980 (1.2976-1.2984)
27.985-28.006 (1.1018-1.1026)
29.985-30.006 (1.1805-1.1813)
0.020-0.061 (0.0008-0.0024)
0.020-0.061 (0.0008-0.0024)
27.967-27.980 (0.1011-1.1016)
29.950-29.975 (1.1791-1.1801)
0.005-0.039 (0.0002-0.0015)
0.010-0.056 (0.0004-0.0022)
5.43-5.50 (0.214-0.217)
6.43-6.50 (0.253-0.256)
5.43-5.50 (0.214-0.217)
14.000-14.018 (0.5112-0.5519)
14.000-14.018 (0.5112-0.5519)
14.000-14.018 (0.5112-0.5519)
13.957-13.968 (0.5495-0.5499)
13.957-13.968 (0.5495-0.5499)
13.957-13.968 (0.5495-0.5499)
| 31.04 (1.222)
33.04 (1.301)
30.93 (1.218)
32.93 (1.296)
28.02 (1.103)
30.02 (1.182)
0.10 (0.004)
0.10 (0.004)
27.94 (1.100)
29.92 (1.178)
0.06 (0.002)
0.06 (0.002)
5.1 (0.20)
6.1 (0.24)
5.1 (0.20)
14.04 (0.553)
14.04 (0.553)
14.04 (0.553)
13.90 (0.547)
13.90 (0.547)
13.90 (0.547)
|
1-9
Коленчатый вал
Наименование
| Стандарт
| Сервисный лимит
| Connecting rod small end I.D.
Connecting rod big end side clearance
Crankshaft runout (1)
Crankpin oil clearance
Crankpin bearing selection
Main journal oil clearance
Main journal bearing selection
| 20.016-20.034 (0.7880-0.7887)
0.05-0.20 (0.002-0.008)
-
0.028-0.052 (0.0011-0.0020)
Смотри стр. 10-21
0.021-0.045 (0.008-0.0018)
Смотри стр. 10-20
| 20.08 (0.791)
0.3 (0.01)
0.03 (0.001)
0.08 (0.003)
-
0.08 (0.003)
-
|
Генератор
Alternator shaft collar spring free height
| 2.1 (0.08)
| 1.8 (0.07)
|
1-10
Wheels/Tires
Наименование
| Стандарт
| Сервисный лимит
| Minimum tire tread depth (FR)
(RR)
Cold tire pressure Driver only (FR)
Driver only (RR)
Driver and passenger (FR)
Driver and passenger (RR)
Front and rear axle runout
Front and rear wheel rim runout (Radial)
(Axial)
Wheel balance weight (Front)
(Rear)
Drive chain slack
Drive chain size/link (DID)
(RK)
| -
-
250 kPa (2.5 kg, 36psi)
290 kPa (2.9 kg, 42psi)
250 kPa (2.5 kg, 36psi)
290 kPa (2.9 kg, 42psi)
-
-
-
-
-
15-25 (0.6-1.0)
DID50ZV/114
RK50LFO/114
| 1.5 (0.06)
2.0 (0.08)
-
-
-
-
0.2 (0.01)
2.0 (0.08)
2.0 (0.08)
60 g (2.1 oz)
60 g (2.1 oz)
-
-
-
|
Front Suspension
Fork spring free length
Fork spring direction
Fork tube runout
Recommended fork oil
Fork oil level
Fork oil capacity
Steering bearing preload
| 446.3 (17.57)
Tapered wound coil facing down
-
Fork fluid
173 (6.8)
418 cm2 (14.1 US oz, 11.8 lmp oz)
1.1-1.6 kg (2.43-3.53 lb)
| 437.4 (17.22)
-
0.2 (0.01)
-
-
-
-
|
Rear Suspension
Damper compressed gas
Damper drilling point
| Nitrogen
13 (0.5)
| -
-
|
1-11
Тормоза
Наименование
| Стандарт
| Сервисный лимит
| Перед
Зад
| Тормозная жидкость
Brake pad wear indicator (1)
Brake disc thichness
Brake disc runout
Master cylinder I.D.
Caliper piston O.D.
Caliper cylinder I.D. (22.6 mm bore)
(25.4 mm bore)
(27.0 mm bore)
Caliper piston O.D. (22.6 mm bore)
(25.4 mm bore)
(27.0 mm bore)
Secondary master cylinder I.D.
Secondary master piston O.D.
Тормозная жидкость
Brake pedal height
Brake pad wear indicator (2)
Brake disc thichness
Brake disc runout
Master cylinder I.D.
Caliper piston O.D.
Caliper cylinder I.D. (22.6 mm bore)
(25.4 mm bore)
(27.0 mm bore)
Caliper piston O.D. (22.6 mm bore)
(25.4 mm bore)
(27.0 mm bore)
| DOT 4
-
5.0 (0.20)
-
12.700-12.743 (0.5000-0.5017)
12.657-12.684 (0.4983-0.4994)
22.650-22.700 (0.8917-0.8937)
25.400-25.450 (1.0000-1.0020)
27.000-27.050 (1.0630-1.0650)
22.585-22.618 (0.8892-0.8905)
25.318-25.368 (0.9968-0.9987)
26.916-26.968 (1.0597-1.0617)
12.700-12.743 (0.5000-0.5017)
12.657-12.684 (0.4983-0.4994)
DOT 4
75 (3.0)
-
5.0 (0.20)
-
17.460-17.503 (0.6874-0.6891)
17.417-17.444 (0.6857-0.6868)
22.650-22.700 (0.8917-0.8937)
25.400-25.450 (1.0000-1.0020)
27.000-27.050 (1.0630-1.0650)
22.585-22.618 (0.8892-0.8905)
25.318-25.368 (0.9968-0.9987)
26.916-26.968 (1.0597-1.0617)
| -
To the groove
4.0 (0.16)
0.30 (0.012)
12.76 (0.502)
6.65 (0.498)
22.710 (0.8941)
25.460 (1.0024)
27.060 (1.0654)
22.560 (0.8882)
25.310 (0.9965)
26.910 (1.0594)
12.76 (0.502)
12.65 (0.498)
-
-
To the groove
4.0 (0.16)
0.30 (0.012)
17.515 (0.6896)
17.405 (0.6852)
22.710 (0.8941)
25.460 (1.0024)
27.060 (1.0654)
22.560 (0.8882)
25.310 (0.9965)
26.910 (1.0594)
| | | | | Battery/Charging System
Alternator/charging coil resistance (At 20oC/68oF)
Alternator field coil resistance (At 20oC/68oF)
Regulator/rectifier regulated voltage
Battery capacity
Specified current leakage
Battery specific gravity (Fully charging)
(Needs charging)
| 0~1.0
0~4.0
12.6-15.0V/5,000 min-1 (rpm)
12V-14Ah
0.1 mA max.
0.2 1.270-1.290
0.3 Below 1.260
| -
-
-
-
-
-
-
|
1-12
Система зажигания
Наименование
| Стандарт
| Сервисный лимит
| Свечи зажигания (Стандарт: NGK)
(Стандарт: NIPPONDENSO)
Зазор электродов на свечах
Ignition timing “F” mark (Except SW, type)
(SW type)
Full advance (Except G, F, SW, AR type)
(G, F, SW, AR type)
Ignition coil resistance (Primary: At 20oC/68oF)
(Secondary with plug cap)
(Secondary without plug cap)
Pulse generator resistance (At 20oC/68oF)
| DPR9EA-9
X27EPR-U9
0.8-0.9 mm (0.03-0.04 in)
10o BTDC/1,000 min-1 (rpm)
5o BTDC/1,000 min-1 (rpm)
40o BTDC/5,000 min-1 (rpm)
37o BTDC/9,500 min-1 (rpm)
2.5-3.2
21-27
11-17
460-580
| -
-
-
-
-
-
-
-
-
-
-
| Стартер
Starter motor brush length
| 12.0-13.0 mm (0.47-0.51 in)
| 6.5 mm (0.26 in)
| Lights/Meters/Switches
Main fuse
Fuse (Except G type)
(G type)
Headlight (High/Low beam; E type)
(High/Low beam; Except E, IT, U, type)
(High/Low beam; IT type)
(High/Low beam; U type)
Tail/brake light
Position light (Except U type)
Front turn signal light
Rear turn signal light
Instrument light
Oil pressure warning indicator
Side stand warning indicator
High beam indicator
Turn signal indicator
Neutral indicator
Fuel unit resistance (At full level)
(At low level)
Coolant temperature sensor resistance (50oC/122oF)
(80oC/176oF)
(120oC/248oF)
Fan motor switch start to close (ON)
Stop opening
| 30A
10A x 5, 20A x 1
10A x 6, 20A x 1
12V-60/55W X 2
12V-60/55W X 1, 12V60W x 1
12V-60/55W X 1
12V-45/45W X 2
12V-5/21W x 2
12V-5W
12V-21W x 2
12V-21W x 2
12V-1.7W x 4
12V-3.4W
12V-3.4W
12V-3.4W
12V-3.4W x 2
12V-3.4W
10
90
130-180
45-60
10-20
98-102oC (208-216oF)
93-97oC (199-207oF)
|
|
1-13
Torque Values
Standard
Fasteners Type
| Torque
N*m (kg-m, ft-lb)
| Fasteners Type
| Torque
N*m (kg-m, ft-lb)
| 5 mm hex bolt and nut
6 mm hex bolt and nut
8 mm hex bolt and nut
10 mm hex bolt and nut
12 mm hex bolt and nut
| 5 (0.5, 3.6)
10 (1.0. 7)
22 (2.2, 16)
35 (3.5, 25)
55 (5.5, 40)
| 5 mm screw
6 mm screw
6 mm flange bolt (8 mm head)
6 mm flange bolt (10 mm head) and nut
8 mm flange bolt and nut
10 mm flange bolt and nut
| 4 (0.4, 2.9)
9 (0.9, 6.5)
9 (0.9, 6.5)
12 (1.2, 9)
27 (2.7, 20)
40 (4.0, 29)
|
Torque specifications listed below are for important fasteners. Other should be tightened to standard torque values listed above.
Notes:
1. Apply sealant to the threads.
2. Apply a locking agent to the threads.
3. Apply molybdenum disulfide oil to the threads and flange surface.
4. Stake.
5. Apply oil to the threads and flange surface.
6. Apply clean engine oil to the O-ring.
7. Apply grease to the threads and flange surface.
8. UBS bolt.
9. U-nut.
10. ALOC bolt.
Engine
Item
| Q’ty
| Thread
Dia. (mm)
| Torque
N*m (kg-m, ft-lb)
| Remarks
| Maintenance:
Timing hole cap
Spark plug
Lubrication System:
Oil filter boss
Oil filter cartridge
Oil drain plug
Oil pass plate
Oil pipe C special bolt
Oil pump driven sprocket bolt
Oil pump assembly flange bolt
Oil pressure switch
Oil pressure switch connector bolt
Fuel System:
Carburetor connecting nut, 6 mm
5 mm
Cooling System:
Water pump flange bolt
Water pipe D flange bolt
|
|
PT 1/8
|
18 (1.8, 13)
15 (1.5, 11)
18 (1.8, 13)
10 (1.0, 7)
30 (3.0, 22)
12 (1.2, 9)
12 (1.2, 9)
15 (1.5, 11)
13 (1.3, 9)
12 (1.2, 9)
2.2 (0.22, 1.6)
10 (1.0, 7)
5.2 (0.52, 3.8)
13 (1.3, 9)
13 (1.3, 9)
|
Note 7
Note 2
Note 5
Note 2
Note 2
Note 2
Note 1
|
1-14
Engine (Cont’d)
Item
| Q’ty
| Thread
Dia. (mm)
| Torque
N*m (kg-m, ft-lb)
| Remarks
| Cylinder Head/Valves:
Cylinder Head flange cap nut
Cylinder Head flange nut
Cylinder Head socket bolt
Cylinder Head sealing bolt
Vacuum port socket bolt
Camshaft holder flange bolt
Cylinder Head cover bolt
Boost joint
Cam sprocket bolt
Valve adjuster screw lock nut
Cam chain tensioner bracket bolt
Rocker arm guide bolt
Clutch/Gearshift Linkage:
Clutch center lock nut
Clutch spring bolt
Clutch slave cylinder bleeder screw
Shift fork shaft stopper plate bolt
Shift drum center bolt
Gearshift spindle return spring pin
Drive sprocket special bolt
Clutch slave cylinder oil bolt
Crankshaft/Transmission
Crankcase main journal bolt
Crankcase flange bolt
Crankcase sealing bolt
Connecting rod nut
Balancer shaft holder flange bolt
Charging System/Alternator:
Alternator base flange bolt
Alternator assembly flange socket bolt
Alternator shaft flange nut
Ignition System
Pulse generator rotor flange bolt
Lights/Meters/Switches
Neutral switch
Neutral switch terminal nut
Other
General torque SH flange bolt
SHF flange bolt
|
-
-
|
|
45 (4.5, 33)
45 (4.5, 33)
26 (2.6, 19)
32 (3.2, 23)
3 (0.30, 2.2)
14 (1.4, 10)
10 (1.0, 7)
2.5 (0.25, 1.8)
20 (2.0, 14)
23 (2.3, 17)
14 (1.4, 10)
12 (1.2, 9)
128 (12.8, 93)
12 (1.2, 9)
8 (0.8, 5.8)
12 (1.2, 9)
23 (2.3, 17)
22 (2.2, 16)
54 (5.4, 39)
35 (3.5, 25)
37 (3.7, 27)
39 (3.9, 28)
24 (2.4, 17)
30 (3.0, 22)
12 (1.2, 9)
35 (3.5, 25)
12 (1.2, 9)
25 (2.5, 18)
8 (0.8, 5.8)
49 (4.9, 35)
49 (4.9, 35)
12 (1.2, 9)
2.2 (0.22, 1.6)
10 (1.0, 7)
12 (1.2, 9)
|
Note 5
Note 5
Note 2
Note 2, 8
Note 5
Note 8
Note 5
Note 2
Note 2
Note 8
Note 5
Note 1
Note 2
Note 5
Note 2
|
1-15
Frame
Item
| Q’ty
| Thread
Dia. (mm)
| Torque
N*m (kg-m, ft-lb)
| Remarks
| Frame/Body Panels/Exhaust System:
Exhaust pipe joint nut
Muffler band bolt
Muffler stay flange nut
Step holder bolt
Center stand bolt
Side stand pivot bolt
Side stand pivot lock nut
Side stand bracket bolt
Grub rail mounting bolt
Lubrication System
Oil cooler pipe joint
Fuel system:
Fuel valve
Fuel tank cap
Fuel unit
Fuel tank mounting bolt
Fuel tank pivot nut
Cooling system:
Fan motor switch
Water hose joint
Water hose band
Engine Mounting:
Front engine hanger bolt/nut (Upper)
Front engine hanger bolt/nut (Lower)
Rear engine hanger bolt/nut (Upper)
Rear engine hanger bolt/nut (Lower)
Engine hanger adjusting bolt
Engine hanger adjusting bolt lock nut
Clutch/Gearshift Linkage:
Clutch master cylinder holder bolt
Clutch master cylinder cap screw
Clutch lever pivot bolt
Clutch lever pivot nut
Clutch switch screw
Gearshift pedal arm pinch bolt
Gearshift pedal arm pivot bolt
Wheels:
Front axle bolt
Front axle holder bolt
Front brake disc bolt
Rear axle nut
Rear brake disc bolt
Driven sprocket nut
Front Suspension:
Steering stem nut
Top thread A
Top thread B
Top bridge pinch bolt
Bottom bridge pinch bolt
Handlebar pivot pinch bolt
Handlebar weight mounting screw
|
|
|
17 (1.7, 12)
22 (2.2, 16)
22 (2.2, 16)
33 (3.3, 24)
50 (5.0, 36)
8 (0.8, 5.8)
40 (4.0, 29)
65 (6.5, 47)
35 (3.5, 2.5)
9 (0.9, 6.5)
10 (1.0, 7)
3 (0.30, 2.2)
10 (1.0, 7)
10 (1.0, 7)
10 (1.0, 7)
18 (1.8, 13)
9 (0.9, 6.5)
1.0-1.5 (0.10-0.15, 0.7-1.1)
45 (4.5, 33)
45 (4.5, 33)
55 (5.5, 40)
55 (5.5, 40)
8 (0.8, 5.8)
25 (2.5, 18)
12 (1.2, 9)
1.5 (0.15, 1.1)
0.8 (0.08, 0.6)
5.9 (0.59, 4.3)
1.2 (0.12, 0.8)
16 (1.6, 12)
27 (2.7, 20)
59 (5.9, 43)
22 (2.2, 16)
42 (4.2, 30)
93 (9.3, 67)
42 (4.2, 30)
110 (11.0, 78)
103 (10.3, 96)
25 (2.5, 18) ------------ -------
_________________|
23 (2.3, 17)
49 (4.9, 35)
27 (2.7, 20)
10 (1.0, 7)
|
Note 9
Note 9
Note 9
Note 1
Note 10
Note 10
Note 9
See page 11-18
|
1-16
Frame (Cont’d)
Item
| Q’ty
| Thread
Dia. (mm)
| Torque
N*m (kg-m, ft-lb)
| Remarks
| Fork:
Fork oil drain bolt
Fork socket bolt
Fork cap bolt
Fork damper rod lock nut
Secondary master cylinder link rod bracket bolt
Rear Suspension:
Swingarm pivot nut
Drive chain adjuster lock nut
Rear shock absorber mounting bolt/nut
Shock link bolt (Frame side)
Shock link bolt (Shock arm side)
Shock arm bolt (Swingarm side)
Brake System:
Front brake master cylinder holder bolt
Front brake master cylinder cap screw
Front brake lever pivot bolt
Front brake lever pivot nut
Front brake lever adjuster socket bolt
Front brake switch screw
Right front brake caliper mounting bolt
Left front brake caliper lower mounting bolt
Caliper body B mounting bolt
Brake caliper main side pin
Brake caliper slide pin
Pad pin
Caliper bleeder screw
Secondary master cylinder mounting bolt
Secondary master cylinder push rod joint nut
Secondary master cylinder orifice bolt
Brake link arm bolt/nut
Rear master cylinder mounting bolt
Rear master cylinder reservoir
Rear master cylinder push rod lock nut
Rear master cylinder reservoir joint screw
Brake hose oil bolt
Brake pipe bolt
Brake hose joint mounting bolt
Brake hose clamp mounting bolt
Other Fasteners:
Ignition switch torx bolt
|
|
|
8 (0.8, 5.8)
20 (2.0, 14)
23 (2.3, 17)
20 (2.0, 14)
27 (2.7, 20)
108 (10.8, 78)
22 (2.2, 16)
42 (4.2, 30)
59 (5.9, 43)
42 (4.2, 30)
42 (4.2, 30)
12 (1.2, 9)
1.5 (0.15, 1.1)
0.8 (0.08, 0.6)
5.9 (0.59, 4.3)
3.9 (0.39, 2.9)
1.2 (0.12, 0.8)
27 (2.7, 20)
27 (2.7, 20)
32 (3.2, 23)
27 (2.7, 20)
23 (2.3, 17)
23 (2.3, 17)
5.4 (0.54, 4.0)
12 (1.2, 9)
18 (1.8, 13)
5.4 (0.54, 4.0)
27 (2.7, 20)
12 (1.2, 9)
12 (1.2, 9)
18 (1.8, 13)
1.5 (0.15, 1.1)
35 (3.5, 25)
17 (1.7, 12)
12 (1.2, 9)
12 (1.2, 9)
25 (2.5, 18)
|
Note 10
Note 9
Note 9
Note 9
Note 9
Note 10
Note 10
Note 10
Note 10
Note 5
Note 10
|
1-17
Инструмент
The marked “*” is newly designed tool.
Специальный
Описание
| Номер инструмента
| Applicability
| Maintenance:
Oil filter wrench
Lock wrench
Drive chain cutter
*- Link plate holder
Fuel System:
Pilot screw wrench
Pilot screw wrench
Cylinder Head/Valves
Valve guide reamer, 5.510 mm
Cylinder/Piston
*Piston ring compressor
Piston base
Front Wheel/Suspension/Steering:
Oil seal driver
Oil seal driver attachment
Steeping stem socket
Bearing race remover
Steering stem driver
Ball race remover
- Remover attachment
- Remover handle
Rear Wheel/Suspension:
Bearing remover set
- Remover handle
- Sliding weight
Driver shaft
Bearing remover attachment
Driver attachment, 28x30 mm
Driver pin
Brake System:
Snap ring pliers
Electrical Equipment:
Peak voltage adaptor
|
07HAA-PJ70100
07GMA-ML70120
07HMH-MR10102
07PMH-MZ20110
07908-4220201
07KMA-MS60101
07984-2000001
07PME-MZ20100
07958-250001
07947-KA50100
07947-KF00100
07916-3710101
07946-3710500
07946-MB00000
07953-MJ10000
07953-MJ10100
07953-MJ10200
07936-3710300
07936-3710100
07741-0010201
07946-MJ00100
07GMD-KT70200
07946-1870100
07GMD-KT80100
07914-3230001
07HGJ-0020100
|
Кроме типа SW
Тип SW
Two required
Two required
|
1-18
Common
Описание
| Номер инструмента
| Примечание
| Система смазки
Oil pressure gauge
Oil pressure gauge attachment
Fuel system:
Float level Gauge
Cylinder Head/Valves:
Valve spring compressor
Valve guide remover, 5.5 mm
Valve guide driver
Valve seat cutter
Seat cutter, 33 mm (45o IN)
Seat cutter, 27.5 mm (45o IN)
Flat cutter, 33 mm (32o IN)
28 mm (32o EX)
Interior cutter, 30 mm (60o IN/EX)
Cutter holder, 5.5 mm
Clutch/Gearshift Linkage:
Clutch center holder
Extension bar
Crankshaft/Transmission:
Universal bearing puller
Attachment, 37x40mm
Inner driver C
Attachment, 25 mm
Pilot, 17 mm
Front wheel/Suspension/Steering:
Bearing remover head, 20 mm
Bearing remover shaft
Driver
Attachment, 42x47 mm
Attachment, 52x55 mm
Pilot, 20 mm
Extension bar
Rear Wheel/Suspension:
Bearing remover head, 20 mm
Bearing remover shaft
Driver
Attachment, 32x35 mm
Attachment, 37x40 mm
Attachment, 52x55 mm
Attachment, 62x68 mm
Pilot, 15 mm
Pilot, 17 mm
Pilot, 20 mm
Pilot, 22 mm
Pilot, 25 mm
Driver attachment outer, 24x26 mm
Electrical Equipment:
Torx driver bit (T40)
Digital multimeter (KOWA)
Analogue tester
|
07506-3000000
07510-4220100
07401-0010000
07757-0010000
07742-0010100
07743-0020000
07780-0010800
07780-0010200
07780-0012900
07780-0012100
07780-0014000
07781-0010101
07724-0050001
07716-0020500
07631-0010000
07746-0010200
07746-0030100
07746-0030200
07746-0040400
07746-0050600
07746-0050000
07749-0010000
07746-0010300
07746-0010400
07746-0040500
07716-0020500
07746-0050600
07746-0050000
07749-0010000
07746-0010100
07746-0010200
07746-0010400
07746-0010500
07746-0040300
07746-0040400
07746-0040500
07746-0041000
07746-0040600
07746-0010700
07703-0010100
07411-0020000
07308-00200001 (SANWA)
Or TH-5H (KOWA)
|
или эквивалент
|
1-19
Lubrication & Seal Points
Engine
Location
| Material
| Remarks
| Crankcase mating surface
Oil pressure switch threads
Alternator base tightening bolt threads
Drive chain guide plate bolt threads
| Liquid sealant
(Three-Bond 1207 or equivalent)
| -Wipe off the excess sealant
- Do not apply sealant to near the bearing
Apply only the area shown
| Main bearing surface
Connecting rod bearing surface
Crankshaft thrust surface
Camshaft bearing surface and thrust surface
Rocker arm slipper surface, guide area
Rocker arm spherical bearing surface
M3/4 gear, C5, C6 gear shift fork groove
Valve stem (valve guide sliding surface)
Primary driven gear surface
Starter reduction shaft sliding surface
| Molybdenum disulfide oil (A mixture of ½ engine oil and ½ molybdenum disulfide grease)
|
|
1-20
Engine (Cont’d)
Location
| Material
| Remarks
| Ignition pulse generator grommet
Cylinder head semi-circular cut-out
| Sealant
|
| Cylinder head cover breather plate bolt threads
Cylinder head sealing bolt threads
Cam sprocket bolt threads
Shift drum bearing set plate bolt threads
Lower crankcase sealing bolt threads (10 mm/20 mm)
Ignition pulse generator rotor bolt threads
Alternator chain guide bolt threads
Alternator chain tensioner mounting bolt threads
Oil pump chain guide bolt threads
Oil pass plate bolt threads
Oil pump driven sprocket bolt threads
Oil pipe C mounting bolt threads
Shift fork shaft stopper plate bolt threads
Oil filter boss
Shift fork shaft stopper plate bolt threads
Drive chain guide plate bolt threads
| Locking agent
| Clean and apply to the threads 6.5 +/- 1mm
| Clutch disc surface
Piston sliding surface and piston pin bore
Piston rings and ring grooves
Oil pass plate seal
Cylinder head nut threads and seating surface
Connecting rod nut threads and seating surface
Main journal UBS bolt threads and seating surface
Oil filter cartridge O-Ring
Clutch center lock nut threads and seating surface
Valve adjusting screw threads
Starter one-way clutch sliding lock surface
Alternator damper spline area
Alternator shaft nut threads and seating surface
Clutch joint piece
Each gear teeth and rotating surface
Oil strainer packing
O-rings
Each bearings
| Engine oil
|
| Oil seal lips
Balancer damper rubber fitting area
Timing hole cap threads
| Multi-purpose grease
|
| Clutch slave cylinder piston seal
| DOT 4 тормозная жидкость
|
|
1-21
Frame
Location
| Material
| Remarks
| Steering stem bearing and dust seal lips
Left second master cylinder link needle bearings and oil seal
Wheel bearing dust seal lips
Fork bottom case needle bearings
Secondary master cylinder arm bearings
Secondary master cylinder arm oil seals
Swingarm pivot nut seating surface
Shock arm/shock link bearing and oil seal
Rear wheel and driven flange sliding area
Swingarm pivot bearing/dust seal
Wheel axle and swingarm outer surface
Throttle cable end
Center stand pivot surface
Side stand pivot surface
Brake pedal pivot
Gearshift pedal pivot
Seat lock striker
Dust seal lips
| Multi-purpose grease
|
Apply thin coat of grease
| Handlebar (throttle grip sliding surface)
Swingarm pivot dust seal lips
Swingarm pivot needle bearings
Shock arm pivot needle bearings/dust seal lips
Shock link pivot needle bearings/dust seal lips
Shock absorber lower mount dust seal lips
Shock absorber lower mount needle bearing
Side stand pivot sliding surface
| Molybdenum disulfide grease
|
| Rear shock absorber upper metal bushing
| Molybdenum paste
|
| Steering stem top threads
Brake flare pipe threads
| Engine oil
|
| Handle grip inside surface
| Honda Bond A
|
| Brake lever pivot and piston contact area
Brake caliper slide pin and boot inside
Caliper dust seal
Rear master cylinder push rod tips/boot inside
Secondary master cylinder push rod tips/boot inside
| Silicon grease
|
| Brake caliper slide pin threads
Fork socket bolt threads
| Locking agent
|
| Fork cap O-ring
Fork oil seal lips
| Fork fluid
|
| Brake master cylinder piston and cup
Clutch master cylinder piston and cup
Brake caliper piston and seal
| DOT 4 тормозная жидкость
|
| Fan motor switch threads
| Sealant
|
|
1-22
Cable & Harness Routing
1-23
1-24
1-25
1-26
1-27
1-28
1-29
1-30
1-31
Вторичная система подачи воздуха (SW, AR типы)
1-32
|