Date completed at:

Mileage completed at:

Year (from manufacture) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Coolant Every two years / 24k 3 3 3 3 3 3 3 3 3
Brake lines Replace/4yrs 3 3 3 3
Fuel lines Replace/4yrs 3 3 3 3

64001 103000

67729 109000
13000

11806 19000

15534 25000

19263 31000

22991 37000

26719 43000

30447 49000

34175 55000

37904 61000

41632 67000

45360 73000

49088 79000

52817 85000

56545 91000

60273 97000
1000

7000
Kilometers

4350

8078
621
Miles

Air filter/surge tank Clean (replace if necessary) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Battery Float charge ~12.7 volts 1 1 1 1 1 1 1 1 1
Battery terminals Clean / Vaseline lube 2 2 2 2 2 2 2 2 2
Brake discs Check Thick (min 4.5mm) & gouging 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Brake pads Check Thick (min 0.5mm) & gouging 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Brake/clutch lever pivot Lube (chain lube…engine oil…) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Brake/shift pedal shaft Lube (chain lube…engine oil…) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Cable (Thrtl/Spd/Cltch/Chke) Lube (chain lube…engine oil…) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Carburetor Synchronization 4 4 4 4 4 4 4 4 4
Clutch Friction plate limit 2.8mm 1 1 1 1 1 1
Clutch lever 2-3mm freeplay (at cable connection) 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Crankcase vents Check hose for damage/oil buildup 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Drive chain EVERY 600 MILES Lube (chain) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Engine oil when engine is warm 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
Engine oil filter 3 3 3 3 3 3 3 3 3 3
Exhaust Check for leaks 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Fittings/fasteners 1 1 1 1 1 1 1 1 1
Front fork oil (replace) 3 3 3 3 3
Front fork oil seals (replace) 1 1 3 1 3 1 3 1 3
Fuel filter (replace) 3 3 3
Rear shock absorber Inspect (leaks, free play) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Rear suspension link pivots Lube (molybdenum disulfibe grease) 2 2 2 2 2 2 2 2 2
Sidestand pivot Lube (chain lube…engine oil…) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Sidestand switch 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Spark plugs Check/clean/gap (0.7-0.8mm)/replace 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3
Steering bearings Lube (lithium soap grease) 2 2 2 2
Swing arm pivot bearing Lube (molybdenum disulfibe grease) 1 2 1 2 1 2 1 2 1
Valve Clearance Check/adjust 1 1 1
Wheel bearings Free spinning else replace 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Check (replace if necessary) 1 Replace 3
Clean and/or Lube 2 Adjust 4
Nut size Head Bolt-shaft General torque spec
size diameter Nm ft-lb
10mm 6mm 6 4.3
12mm 8mm 15 11
14mm 10mm 30 22
17mm 12mm 55 40
19mm 14mm 85 61
22mm 16mm 130 94
Part Thread Nm Ft-lb Note
Brake caliper bleed screw m8 6 4.3
Brake disc to front wheel m8 23 17 Lock-tite
Brake disc to rear wheel m8 20 14 Lock-tite
Brake front caliper to fork m10 40 29
brake front master cylinder m6 13 9.4
Brake hose union bolt m10 30 22
Brake line - union bolt m10 30 22
Brake rear caliper to bracket m10 40 29
Brake rear master cylinder m8 23 17
Brake rear reservoir m6 5 3.6
Engine mount bolt front m10 54 39
Engine mount bolt rear lower m10 48 35
Engine mount bolt rear upper m10 48 35
Engine pinch bolt front left m10 64 46
Footrest bracket and frame m8 30 22
Frame and side panel stay m8 30 22
Front wheel axle m16 65 47
Front wheel axle pinch bolt m8 20 14
Fuel cock to fuel tank m6 7 5.1
Fuel sender to fuel tank m6 7 5.1
Handle boss and handlebar m8 28 20
Handle boss and inner tube m6 13 9.4
Handle boss and upper triple m6 13 9.4
Lower triple and inner tube m10 38 27
Rear shock and bracket m10 40 29
Rear shock and relay arm m10 40 29
Rear sprocket m10 60 43
Rear tension bar m8 30 22
Rear wheel axle nut m18 117 85
Sidestand bolt & nut m10 39 28
Sidestand bolt & frame m10 46 33
Steering stem (ring nut) m25 3 2.2 First tighten to 52nm/38ft-lb. Loosen. Tighten to spec.
swingarm conrod-to-swingarm m10 48 35
Swingarm pivot shaft m16 90 65
Swingarm relay arm-to-conrod m10 48 35
Swingarm relay arm-to-frame m10 48 35
Upper triple and inner tube m8 30 22
Upper triple and steering stem m22 110 80
 Part Type Thread Qty Nm ft-lb Lube
AC magneto cover bolt m6 5 12 8.7
AC magneto rotor bolt m12 1 130 94
Air filter case bolt m6 1 10 7.2
Air filter case cover screw m5 8 5 3.6
Balance pipe bolt m6 2 7 5.1
Camshaft cap bolt m6 24 10 7.2
Carburetor joint bolt m6 8 10 7.2
Chain guide (intake side) bolt m6 2 10 7.2 Lock-tite
Clutch boss nut m18 1 70 50 Lock Washer
Clutch cover bolt m6 10 12 8.7
Clutch cover screw m5 4 4 2.9 Lock-tite
Clutch spring screw m6 6 8 5.8
Conduction element bolt m6 2 7 5.1
Connecting rod nut m7 8 15nm+90degree 11ft-lb+90degree Molybdenum Disulfide Grease
Crank bearing retainer bolt m6 2 10 7.2 Lock-tite
Crankcase stud bolt m8 12 12.5 9 Engine Oil
Crankcase bolt m8 13 24 17 Molybdenum Disulfide Grease
Crankcase bolt m6 21 12 8.7 Engine Oil
Crankcase cover (left) bolt m6 5 10 7.2
Crankcase cover (left) screw m5 4 4 2.9 Lock-tite
Crankcase plug plug m16 2 8 5.8 Engine Oil
Cylinder head nut m8 12 35 25 Engine Oil
Cylinder head cover bolt m6 8 10 7.2
Drive sprocket nut m18 1 70 50 Lock Washer
Exhaust - head studs stud bolt m6 8 10 7.2 Engine Oil
Exhaust - muffler bolt m8 1 20 14
Exhaust pipe at muffler bolt m8 1 20 14
Exhaust pipe stay bolt m8 1 20 14
Guide bar stopper bolt m6 1 10 7.2 Lock-tite
Joint bolt m6 4 10 7.2
Lead holder screw m6 1 7 5.1
Neutral switch screw m6 2 4 2.9
Oil baffle plate screw m6 6 7 5.1 Lock-tite
Oil cooler union bolt m20 1 63 45 Engine Oil
Oil delivery pipe bolt m6 1 10 7.2
Oil delivery pipe union bolt m10 2 20 14
Oil drain bolt bolt m14 1 43 31
Oil filter oil filter m20 1 17 12 Engine Oil
Oil level switch bolt m6 2 7 5.1
Oil pan bolt m6 14 12 8.7
Oil pump assembly bolt m6 3 10 7.2 Lock-tite
Oil pump cover screw m6 1 7 5.1
Oil strainer housing bolt m6 2 10 7.2 Lock-tite
Pickup coil screw m5 2 5 3.6
Push lever assembly scerw m5 2 4.5 3.3 Lock-tite
Push rod adjuster nut m8 1 16 12
Radiator bolt m6 3 7 5.1
Shift arm bolt m6 1 10 7.2
Shift cam stopper lever bolt m6 1 10 7.2 Lock-tite
Shift pedal adjuster nut m8 2 10 7.2 Caution: 1 is LH thread
Side plate screw m5 1 4 2.9 Lock-tite
Spark plug spark plug m10 4 12.5 9
Starter clutch cover bolt m6 7 12 8.7
Starter clutch cover bolt m10 1 80 58
Starter wheel gear bolt m8 3 30 22 Lock-tite
Stator coil bolt m6 3 10 7.2 Lock-tite
Stopper plate bolt m6 1 10 7.2 Lock-tite
String stopper screw m8 1 22 16 Lock-tite
Thermo switch threaded m16 1 23 17
Thermo unit threaded m8 1 15 11
Thermostatic valve cover bolt m6 2 10 7.2
Timing chain sprocket bolt m7 4 24 17
Timing chain tensioner bolt m6 2 10 7.2
Timing chain tensioner end cap bolt m11 1 20 14
Water pipe bolt m6 4 10 7.2
Water pump bolt m6 2 10 7.2
Water pump cover bolt m6 2 10 7.2
Location
Axle (main/drive)
Brake lever pivot bolt
Camshaft Lobes
Clutch hub fitting area
Clutch hub oil seal
Clutch lever pivot bolt
Connecting rod bearings
Connecting rod bolt/nut
Crankshaft journal
Cylinder head bolt/nut
Engine bearings
Engine:Camshaft cap bolt
Front wheel oil seal
Idle gear inner surface
Oil pump rotor, housing
Oil seal lips
Oil strainer assembly
O-ring
Piston pin
Piston surface
Pivot shaft
Push rod (bearing/washer) and ball
Rear brake pedal shaft
Rear footrest pivot
Rear shock absorber (upper/lower)
Rear wheel oil seal
Shift cam
shift fork/guide bar
shift lever assy
shift pedal
Shift pedal
shift shaft assy
Sidestand sliding joint
started idle gear shaft
Steering bearing and race
Swingarm bearings
Throttle tube inner surface
Thrust cover (inner)
Transmission gear (wheel/pinion)
Valve lfiter
Valve stem
Valve stem end
Water pump impeller shaft
Lubrication choice
Molybdenum oil
Lithium soap grease
Molybdenum oil
Lithium soap grease
Lithium soap grease
Lithium soap grease
Engine oil
Molybdenum disulfide grease
Engine oil
Engine oil
Engine oil
Engine oil
Lithium soap grease
Engine oil
Engine oil
Lithium soap grease
Lithium soap grease
Lithium soap grease
Engine oil
Engine oil
Molybdenum disulfide grease
Lithium soap grease
Lithium soap grease
Lithium soap grease
Molybdenum disulfide grease
Lithium soap grease
Engine oil
Engine oil
Lithium soap grease
Lithium soap grease
Lithium soap grease
Engine oil
Lithium soap grease
Molybdenum disulfide grease
Lithium soap grease
Molybdenum disulfide grease
Lithium soap grease
Molybdenum disulfide grease
Molybdenum oil
Engine oil
Molybdenum oil
Engine oil
Lithium soap grease
Engine
Compression Pressure 1550kPa 220 psi at 400rpm
engine oil grade >4C >40F 20W40
<15C <60F 10W30
Periodic oil change 2.6L 2.7USqt
with oil filter 2.9L 3.1USqt
total capacity 3.5L 3.7USqt

Radiator
Fluid capacity 1.95L 2.06USqt

Front suspension
Oil capacity .434 litre 14.7 US oz
Oil level 124 mm 4.88 in
Oil type Fork oil 5 WT

Swingarm
Freeplay limits 1mm 0.04 in

Spark plug
Type CR9E / U27ESR-N
Electrode gap 0.7-0.8mm 0.028-0.031in
Resistance Cap 10kOhm

TCI
Resistance 189-231Ohm @ 20C (Yellow-to-blue_

Ignition coil
Spark gap min 6mm
Primary winding resistance 1.87-2.53Ohm @ 20C
Secondary winding 12-18kOhm @ 20C

Charging system
12 V - 8.8 A @ 1300rpm
resistance 0.36 - 0.44 Ohm @ 20C (White-to-White)

Starter System
Minimum brush length 4mm
Commutator min diam 27mm
Coil winding resistance 3.96 - 4.84 Ohm @ 20C
Relay resistance 203 - 248 Ohm @ 20C

Fuel pump relay

Relay resistance 203 - 248 Ohm @ 20C

Tire Pressure
0-90kg / 0-198lb Front 32 psi Rear 36 psi
90-182kg / 198-401lb Front 36 psi Rear 41 psi
High speeds Front 36 psi Rear 41 psi

Battery
Type YTX12-BS
Capacity 12V / 10 AH