1-13
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.
Frame construction Frame to rear frame
Combined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Installation of rear shock absorber Rear shock absorber to frame
Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle
Tightening of axle holder
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel tank to fuel cock
2-9
TIGHTENING TORQUES
△Handlebar lower holder M12 × 1.25 2 40 4.0 29
△Steering ring nut M28 × 1.0 1 Refer to TIP.
Front fork and damper assembly M51 × 1.5 2 30 3.0 22
Front fork and adjuster M22 × 1.25 2 55 5.5 40
Damper assembly and base valve M42 × 1.5 2 29 2.9 21
Adjuster and damper assembly M12 × 1.25 2 29 2.9 21
Bleed screw (front fork) and base valve M5 × 0.8 2 1 0.1 0.7
△Front fork and front fork protector M6 × 1.0 6 5 0.5 3.6
△Cable guide (front brake hose) and lower bracket M6 × 1.0 1 4 0.4 2.9
△Front fork protector and brake hose holder M6 × 1.0 2 8 0.8 5.8
Throttle cable cap M4 × 0.7 2 1 0.1 0.7
△Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 × 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Clutch lever mounting nut M6 × 1.0 1 4 0.4 2.9
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
△Front brake hose union bolt (brake 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 M8 × 1.25 2 28 2.8 20
Grip cap upper and lower M6 × 1.0 2 4 0.4 2.9
Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 3 0.3 2.2
△Brake caliper (front and rear) and pad pin M10 × 1.0 2 18 1.8 13
△Brake caliper (front and rear) and bleed screw M8 × 1.25 2 6 0.6 4.3
△Front wheel axle and axle nut M16 × 1.5 1 105 10.5 75
△Front wheel axle holder M8 × 1.25 4 21 2.1 15
△Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7
△Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10
Footrest bracket and frame M10 × 1.25 4 55 5.5 40
△Brake pedal mounting M8 × 1.25 1 26 2.6 19
△Rear brake master cylinder and frame M6 × 1.0 2 10 1.0 7.2
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
△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 axle nut M20 × 1.5 1 125 12.5 90
△Nipple (spoke) — 72 3 0.3 2.2
△Driven sprocket and wheel hub M8 × 1.25 6 42 4.2 30
△Disc cover and rear brake caliper M6 × 1.0 2 10 1.0 7.2
△Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Drive chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13
Engine :
△Engine and frame (front) M10 × 1.25 1 64 6.4 46
△Engine and frame (lower) M10 × 1.25 1 64 6.4 46Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
3-17
CHASSIS
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Place a stand under the engine to
raise the front wheel off the
ground. WARNING! Securely
support the vehicle so that
there is no danger of it falling
over.
2. Check:
• Steering stem
Grasp the bottom of the forks and
gently rock the fork assembly
back and forth.
Free play→Adjust steering head.
3. Check:
• Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action→Adjust steer-
ing ring nut.
4. Adjust:
• Steering ring nut
Steering ring nut adjustment
steps:
a. Remove the number plate.
b. Remove the handlebar and upper
bracket.
c. Loosen the steering ring nut "1"
using the steering nut wrench "2".
d. Tighten the steering ring nut "3"
using steering nut wrench "4".
• Apply the lithium soap base grease
on the thread of the steering stem.
• Set the torque wrench to the steer-
ing nut wrench so that they form a
right angle.
e. Loosen the steering ring nut one
turn.
f. Retighten the steering ring nut us-
ing the steering nut wrench.
Avoid over-tightening.
g. Check the steering stem by turn-
ing it lock to lock. If there is any
binding, remove the steering stem
assembly and inspect the steer-
ing bearings.
h. Install the washer "5", upper
bracket "6", washer "7", steering
stem nut "8", handlebar "9", han-
dlebar upper holder "10" and
number plate "11".
• The handlebar upper holder should
be installed with the punched mark
"a" forward.
• Install the handlebar so that the
marks "b" are in place on both
sides.
• Install the handlebar so that the pro-
jection "c" of the handlebar upper
holder is positioned at the mark on
the handlebar as shown.
• Insert the end of the fuel breather
hose "12" into the hole in the steer-
ing stem.
First tighten the bolts on the front
side of the handlebar upper holder,
and then tighten the bolts on the
rear side.
Steering nut wrench:
YU-33975/90890-01403
Steering nut wrench:
YU-33975/90890-01403
Steering ring nut (initial
tightening):
38 Nm (3.8 m•kg, 27
ft•lb)
Steering ring nut (final
tightening):
7 Nm (0.7 m•kg, 5.1
ft•lb)Steering stem nut:
145 Nm (14.5 m•kg, 105
ft•lb)
Handlebar upper holder:
28 Nm (2.8 m•kg, 20
ft•lb)
Pinch bolt (upper brack-
et):
21 Nm (2.1 m•kg, 15
ft•lb)
Number plate:
7 Nm (0.7 m•kg, 5.1
ft•lb)
