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SPECGENERAL SPECIFICATIONS
Carburetor:
Type/Manufacturer TMXø
38SS/MIKUNI
Spark plug:
Type/Manufacturer BR9EG/NGK
Gap 0.5~0.6 mm (0.020~0.024 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 64/19 (3.368)
Secondary reduction system Chain drive
Secondary reduction ratio 48/13 (3.692)
Transmission type Constant mesh, 6-speed
Operation Left foot operation
Gear ratio: 1st 30/13 (2.307)
2nd 28/15 (1.866)
3rd 26/17 (1.529)
4th 27/21 (1.285)
5th 26/23 (1.130)
6th 24/24 (1.000)
Chassis:USA, CDN, ZA, AUS, NZEUROPE
Frame type Semi double cradle¬
Caster angle 25.6° 25.4°
Trail 107 mm (4.21 in) 104 mm (4.09 in)
Tire:
Type With tube
Size (front) 80/100-21 51M
Size (rear) 100/90-19 57M
Tire pressure (front and rear) 100 kPa (1.0 kg/cm2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/Gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
2
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SPECMAINTENANCE SPECIFICATIONS
Item Standard Limit
Wheel:
Front wheel type Spoke wheel…
Rear wheel type Spoke wheel…
Front rim size/Material 21 ´1.60/Aluminum…
Rear rim size/Material 19 ´1.85/Aluminum…
Rim runout limit:
Radial…
2.0 mm (0.08 in)
Lateral … 2.0 mm (0.08 in)
Drive chain:
Type/Manufacturer DID520DMA2 SDH/DAIDO …
Number of links 111 links+joint …
Chain slack 40~50 mm (1.6~2.0 in) …
Chain length (10 links) … 152.5 mm (6.004 in)
Front disc brake:
Disc outside dia. ´Thickness 250 ´3.0 mm (9.84 ´0.12 in)…
Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in)…
Caliper cylinder inside dia. 27.0 mm (1.063 in) ´2…
Brake fluid type DOT #4…
Rear disc brake:
Disc outside dia. ´Thickness 240 ´4.0 mm (9.45 ´0.16 in)…
Deflection limit…
0.15 mm (0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 12.7 mm (0.500 in)…
Caliper cylinder insdie dia. 27.0 mm (1.063 in)…
Brake fluid type DOT #4…
Brake lever & brake pedal:
Brake lever position 95 mm (3.74 in)…
Brake pedal height 5 mm (0.20 in)…
(vertical height above footrest top)
Clutch lever free play (at lever pivot) 2~4 mm (0.08~0.16 in)…
Throttle grip free play 3~5 mm (0.12~0.20 in)…
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SPECMAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the ring nut wrench,
then loosen the ring nut one turn.
2. Retighten the ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
Part to be tightened Thread size Q'tyT ightening torqueNm m•kg ft•lb
Handle crown and outer tube M 8 ´1.25 4 23 2.3 17
Under bracket and outer tube M 8 ´1.25 4 20 2.0 14
Handle crown and steering shaft M24 ´1.0 1 145 14.5 105
Handlebar holder (upper) M 8 ´1.25 4 28 2.8 20
Steering ring nut M28 ´1.0 1 Refer to NOTE
Front fork and cap bolt M48 ´1.0 2 30 3.0 22
Front fork and base valve M30 ´1.0 2 55 5.5 40
Cap bolt and damper rod (front fork) M12 ´1.25 2 29 2.9 21
Bleed screw (front fork) and cap bolt M 5 ´0.8 2 1 0.1 0.7
Front fork and protector M 6 ´1.0 6 10 1.0 7.2
Cable guide (front brake hose) and guide stayM 5 ´0.8 1 4 0.4 2.9
Front fork and brake hose holder M 6 ´1.0 2 10 1.0 7.2
Front fork and hose cover M 8 ´1.25 1 16 1.6 11
Front fork and hose cover M 6 ´1.0 1 7 0.7 5.1
Throttle cable cap M 4 ´0.7 2 1 0.1 0.7
Front brake master cylinder and bracket M 6 ´ 1.0 2 9 0.9 6.5
Brake lever (bolt) M 6 ´1.0 1 6 0.6 4.3
(nut) M 6 ´1.0 1 6 0.6 4.3
Brake lever position locknut M 6 ´1.0 1 5 0.5 3.6
Clutch lever (bolt) M 6 ´1.0 1 2 0.2 1.4
Clutch lever holder M 5 ´0.8 2 4 0.4 2.9
Front brake master cylinder cap M 4 ´0.7 2 2 0.2 1.4
Front brake hose union bolt (master cylinder)M10 ´1.25 1 30 3.0 22
Front brake hose union bolt (caliper) M10 ´1.25 1 30 3.0 22
Front brake caliper and front fork M 8 ´1.25 2 23 2.3 17
Grip cap upper and lower M 6 ´1.0 2 4 0.4 2.9
Brake caliper (front and rear) and pad pin plugM10 ´1.0 1 3 0.3 2.2
Brake caliper (front and rear) and pad pin M10 ´1.0 1 18 1.8 13
Brake caliper (front and rear) and bleed screwM 8 ´1.25 1 6 0.6 4.3
Front wheel axle and nut M16 ´1.5 1 105 10.5 75
Front wheel axle holder M 8 ´1.25 4 23 2.3 17
Front brake disc and wheel hub M 6 ´1.0 6 12 1.2 8.7
Rear brake disc and wheel hub M 6 ´1.0 6 14 1.4 10
Brake pedal mounting M 8 ´1.25 1 26 2.6 19
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SPECMAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q'tyT ightening torqueNm m•kg ft•lb
Rear brake master cylinder and frame M 6 ´1.0 2 10 1.0 7.2
Rear brake reservoir tank and frame M 6 ´1.0 1 7 0.7 5.1
Rear brake hose union bolt (caliper) M10 ´1.25 1 30 3.0 22
Rear brake hose union bolt (master cylinder) M10 ´1.25 1 30 3.0 22
Rear wheel axle and nut M20 ´1.5 1 125 12.5 90
Nipple (spoke) – 72 3 0.3 2.2
Driven sprocket and wheel hub M 8 ´1.25 6 42 4.2 30
Disc cover and rear brake caliper M 6 ´1.0 2 7 0.7 5.1
Protector and rear brake caliper M 6 ´1.0 2 7 0.7 5.1
Engine mounting:
Engine and frame (front) M10 ´1.25 1 69 6.9 50
Engine and frame (lower) M10 ´1.25 1 69 6.9 50
Engine bracket and frame M 8 ´1.25 2 34 3.4 24
Engine bracket and engine M 8 ´1.25 1 34 3.4 24
Pivot shaft and nut M16 ´1.5 1 85 8.5 61
Relay arm and swingarm M14 ´1.5 1 80 8.0 58
Relay arm and connecting rod M14 ´1.5 1 80 8.0 58
Connecting rod and frame M14 ´1.5 1 80 8.0 58
Rear shock absorber and frame M10 ´1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 ´1.25 1 53 5.3 38
Rear frame and frame M 8 ´1.25 3 29 2.9 21
Swingarm and brake hose holder M 5 ´–4 4 0.4 2.9
Chain tensioner mounting M 8 ´1.25 2 19 1.9 13
Chain support and swingarm M 6 ´1.0 3 7 0.7 5.1
Seal guard and swingarm M 5 ´0.8 4 5 0.5 3.6
Fuel tank mounting M 6 ´1.0 2 10 1.0 7.2
Fuel tank and fuel cock M 6 ´1.0 2 7 0.7 5.1
Fuel tank and seat set bracket M 6 ´1.0 1 7 0.7 5.1
Fuel tank and hooking screw (fitting band) M 6 ´1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M 6 ´1.0 4 7 0.7 5.1
Air scoop mounting M 6 ´1.0 8 3 0.3 2.2
Front fender mounting M 6 ´1.0 4 7 0.7 5.1
Rear fender mounting M 6 ´1.0 4 7 0.7 5.1
Side cover mounting M 6 ´1.0 4 7 0.7 5.1
Seat mounting M 6 ´1.0 2 7 0.7 5.1
Number plate M 6 ´1.0 1 7 0.7 5.1
NOTE:
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s- marked portion shall be checked for torque tightening after break-in or before each race.
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