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Система охлаждения




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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

 

 

 

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1-31

Вторичная система подачи воздуха (SW, AR типы)

 

 

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