Honda Crf250l Service Manual

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GENERAL INFORMATIONCOOLING SYSTEM SPECIFICATIONS
CYLINDER HEAD/VAL VES SPECIFICATIONS
Unit: mm (in)
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 1.02  liters (1.08 US qt, 0.90 Imp qt)
At draining 0.74 liter (0 .78 US qt, 0.65 Imp qt)
Reserve tank 0.16 liter (0 .17 US qt, 0.14 Imp qt)
Radiator cap relief pressure 93.2 – 122.6 kPa (0.95 – 1.25 kgf/cm
2, 13.5 – 17.8 psi)
Thermostat Begin to open 81 – 84°C (178 – 183°F)
Fully open 95°C (203°F)
Valve lift 4.5 mm (0 .18 in) minimum
Recommended coolant High quality ethylene glycol antifreeze containing silicate-free  corrosion inhibitors
Standard coolant concentration 1:1 (mixture with distilled water)
ITEM STANDARDSERVICE LIMIT
Cylinder compression at 490 min-1 (rpm) 1,294 kPa (13.2 kgf/cm2, 188 psi) – 
Valve clearance IN0.16 ± 0.03 (0.006 ± 0.001) – 
EX 0.27 ± 0.03 (0.011 ± 0.001) – 
Valve, valve 
guide Valve stem O.D. IN
4.475 – 4.490 (0.1762 – 0.1768) 4.46 (0.176)
EX 4.465 – 4.480 (0.1758 – 0.1764) 4.45 (0.175)
Valve guide I.D. IN/EX 4.500 – 4.512 (0.1772 – 0.1776) 4.540 (0.1787)
Stem-to-guide 
clearance IN
0.010 – 0.037 (0.0004 – 0.0015) 0.07 (0.003)
EX 0.020 – 0.047 (0.0008 – 0.0019) 0.08 (0.003)
Valve guide height IN/EX 13.8 – 14.0 (0.54 – 0.55) – 
Valve seat width IN/EX 0.90 – 1.10 (0.035 – 0.043) 1.50 (0.059)
Valve spring Free length Inner34.58 (1.361) 32.85 (1.293)
Outer 40.37 (1.589) 38.35 (1.510)
Rocker arm, 
rocker arm 
shaft Arm I.D.
IN/EX10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
Shaft O.D. IN/EX9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm-to-shaft 
clearance IN/EX
0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004)
Camshaft Cam lobe height IN 30.931 – 31.171 (1.2178 – 1.2272) 30.911 (1.2170)
EX 30.839 – 31.079 (1.2141 – 1.2236) 30.819 (1.2133)
Camshaft journal O.D. 19.959 – 19.980 (0.7858 – 0.7866) – 
Oil clearance 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Cylinder 
head Camshaft journal area I.D.
20.000 – 20.021 (0.7874 – 0.7882) – 
Warpage –0.05 (0.002)
ITEM STANDARDSERVICE LIMIT
Cylinder I.D. 76.000 – 76.010 (2.9921 – 2.9925) 76.04 (2.994)
Out-of-round –0.010 (0.0004)
Taper –0.010 (0.0004)
Warpage –0.05 (0.002)
Piston, piston 
pin, piston 
ring Piston O.D. at 11 mm (0.4 in) from 
bottom
75.960 – 75.980 (2.9905 – 2.9913) 75.89 (2.988)
Piston pin hole I.D. 17.002 – 17.008 (0.6694 – 0.6696) 17.030 (0.6705)
Piston pin O.D. 16.994 – 17.000 (0.6691 – 0.6693) 16.980 (0.6685)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Piston ring end 
gap Top
0.28 – 0.38 (0.011 – 0.015) 0.40 (0.016)
Second 0.40 – 0.55 (0.016 – 0.022) 0.70 (0.028)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 1.10 (0.043)
Piston ring-to-ring 
groove clearance Top
0.040 – 0.080 (0.0016 – 0.0031) 0.10 (0.004)
Second 0.015 – 0.050 (0.0006 – 0.0020) 0.09 (0.004)
Cylinder-to-piston clearance 0.020 – 0.050 (0.0008 – 0.0020) 0.09 (0.004)
Connecting rod small end I.D. 17.016 – 17.034 (0.6699 – 0.6706) 17.06 (0.672)
Connecting rod-to-piston pin clearance 0.016 – 0.040 (0.0006 – 0.0016) 0.10 (0.004) 
						

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GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS
Unit: mm (in)
ALTERNATOR/STARTER CL UTCH SPECIFICATIONS
Unit: mm (in)
CRANKCASE/CRANKSHAFT/TR ANSMISSION/BALANCER SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Clutch lever freeplay 10 – 20 (0.4 – 0.8) –
Clutch Spring free length 41.5 (1.63) 37.5 (1.48)
Disc thickness Disc A/B 2.30 – 2.50 (0.091 – 0.098) 2.27 (0.089)
Plate warpage Plate A/B –0.30 (0.012)
Clutch outer guide I.D. 20.000 – 20.021 (0.7874 – 0.7882) 20.04 (0.789)
Mainshaft O.D. at clutch outer guide 19.967 – 19.980 (0.7861 – 0.7866) 19.947 (0.7853)
ITEM STANDARDSERVICE LIMIT
Starter driven gear I.D.34.000 – 34.013 (1.3386 – 1.3391) 34.033 (1.3399)
O.D. 51.705 – 51.718 (2.0356 – 2.0361) 51.685 (2.0348)
ITEM STANDARDSERVICE LIMIT
Crankshaft Runout –0.03 (0.001)
Connecting rod big end radial clearance 0.004 – 0.016 (0.0002 – 0.0006) 0.05 (0.002)
Connecting rod big end side clearance 0.05 – 0.50 (0.002 – 0.020) 0.85 (0.033)
Main journal oil clearance 0.018 – 0.045 (0.0007 – 0.0018) 0.075 (0.0030)
Main journal O.D. 33.985 – 34.000 (1.3380 – 1.3386) 33.975 (1.3376)
Main journal bearing support I.D. 38.000 – 38.018 (1.4961 – 1.4968) 38.036 (1.4975)
Transmission Gear I.D. M5, M623.000 – 23.021 (0.9055 – 0.9063) 23.07 (0.908)
C1 23.020 – 23.041 (0.9063 – 0.9071) 23.09 (0.909)
C2 25.000 – 25.021 (0.9843 – 0.9851) 25.04 (0.986)
C3, C4 28.000 – 28.021 (1.1024 – 1.1032) 28.04 (1.104)
Bushing O.D. M5, M6 22.959 – 22.980 (0.9039 – 0.9047) 22.91 (0.902)
C1 22.984 – 23.005 (0.9049 – 0.9057) 22.47 (0.885)
C2 24.959 – 24.980 (0.9826 – 0.9835) 24.90 (0.980)
C3, C4 27.959 – 27.980 (1.1007 – 1.1016) 27.95 (1.100)
Gear-to-bushing 
clearance M5, M6, C2, 
C3, C4
0.020 – 0.062 (0.0008 – 0.0024)
0.10 (0.004)
C1 0.015 – 0.057 (0.0006 – 0.0022) 0.10 (0.004)
Bushing I.D. M5, C1 20.000 – 20.021 (0.7874 – 0.7882) 20.05 (0.789)
C2 22.000 – 22.021 (0.8661 – 0.8670) 22.07 (0.869)
C3 25.000 – 25.021 (0.9843 – 0.9851) 25.04 (0.986)
Mainshaft / 
countershaft O.D. at M5 bushing 19.959 – 19.980 
(0.7858 – 0.7866) 19.91 (0.784)
at C1 bushing 19.959 – 19.980  (0.7858 – 0.7866) 19.91 (0.784)
at C2 bushing 21.959 – 21.980  (0.8645 – 0.8654) 21.91 (0.863)
at C3 bushing 24.959 – 24.980  (0.9826 – 0.9835) 24.90 (0.980)
Bushing-to-shaft 
clearance M5, C1, C2, C3 0.020 – 0.062 (0.0008 – 0.0024)
0.10 (0.004)
Shift fork, 
shift fork 
shaft Shift fork shaft O.D.
11.957 – 11.968 (0.4707 – 0.4712) 11.95 (0.470)
Shift fork I.D. 12.000 – 12.018 (0.4724 – 0.4731) 12.05 (0.474)
Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.82 (0.190)
Shift drum Shift drum O.D. Left side 13.966 – 13.984 (0.5498 – 0.5506) 13.94 (0.549)
Shift drum journal 
I.D. Left side
14.000 – 14.027 (0.5512 – 0.5522) 14.06 (0.554)
Shift drum-to-shift 
drum journal 
clearance Left side
0.016 – 0.061 (0.0006 – 0.0024) 0.08 (0.003) 
						

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GENERAL INFORMATIONFRONT WHEEL/SUSPENSION/S TEERING SPECIFICATIONS
Unit: mm (in)
REAR WHEEL/SUSPENSION SPECIFICATIONS
Unit: mm (in)
BRAKE SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Minimum tire thre ad depth – 3.0 (0.12)
Cold tire pressure Driver only 150 kPa (1.50 kgf/cm
2, 22 psi) –
Driver and passenger 150 kPa (1.50 kgf/cm2, 22 psi)–
Axle runout –0.2 (0.01)
Wheel rim runout Radial –2.0 (0.08)
Axial –2.0 (0.08)
Wheel hub-to-rim distance 23.45 ± 1.0 (0.92 ± 0.04)–
Fork Spring free length (Right side only) 575.0  (22.64) –
Pipe runout –0.20 (0.008)
Recommended fork fluid Honda ULTRA CUSHION OIL 10W or 
equivalent –
Fluid level Right 122 (4.8) –
Left 38 (1.5)
Fluid capacity Right 658 ± 2.5 cm
3 
(22.3 ± 0.08 US oz, 23.2 ± 0.09 Imp oz) –
Left 683 ± 2.5 cm
3 
(23.1 ± 0.08 US oz, 24.0 ± 0.09 Imp oz)
Steering head bearing pre-load 10.6 – 21.2 N  (1.08 – 2.16 kgf, 2.38  – 4.77 lbf) –
ITEM
STANDARDSERVICE LIMIT
Minimum tire thread depth –3.0 (0.12)
Cold tire pressure Driver only 150 kPa (1.50 kgf/cm
2, 22 psi) –
Driver and passenger 150 kPa (1.50 kgf/cm2, 22 psi) –
Axle runout –0.2 (0.01)
Wheel rim runout Radial –2.0 (0.08)
Axial –2.0 (0.08)
Wheel hub-to-rim distance 26.9 ± 1.0 (1.06 ± 0.04)–
Drive chain Size/link DID520VF-106LE –
Slack 25 – 35 (1.0 – 1.4) –
ITEMSTANDARDSERVICE LIMIT
Front Specified brake fluid DOT 3 or DOT 4–
Brake pad wear indicator –To groove
Brake disc thickness 3.3 – 3.7 (0.13 – 0.15)3.0 (0.12)
Brake disc warpage –0.3 (0.01)
Master cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022)
Master piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)
Caliper cylinder I.D. 27.000 – 27.050 (1.0630 – 1.0650) 27.060 (1.0654)
Caliper piston O.D. 26.935 – 26.968 (1.0604 – 1.0617) 26.89 (1.0587)
Rear Specified brake fluid DOT 3 or DOT 4–
Brake pad wear indicator –To groove
Brake disc thickness 4.3 – 4.7 (0.17 – 0.19)4.0 (0.16)
Brake disc warpage –0.3 (0.01)
Master cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022)
Master piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)
Caliper cylinder I.D. 27.000 – 27.050 (1.0630 – 1.0650) 27.060 (1.0654)
Caliper piston O.D. 26.935 – 26.968 (1.0604 – 1.0617) 26.89 (1.0587)
Brake pedal height 64 – 65 (2.52 – 2.56) – 
						

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GENERAL INFORMATION
BATTERY/CHARGING SYST EM SPECIFICATIONS
LIGHTS/METERS/SWITCHES SPECIFICATIONS
TORQUE VALUES
STANDARD TORQUE VALUES
ITEM SPECIFICATIONS
Battery Type YTX7L-BS
Capacity 12 V - 6 Ah (10 HR)
Current leakage 0.34 mA max.
Voltage 
(20°C/68°F) Fully charged
13.0 – 13.2 V
Needs 
charging Below 12.3 V
Charging current Normal 0.6 A/5 – 10 h
Quick 3 A/1 h
Alternator Capacity  0.34 kW/5,000 min
-1 (rpm)
Charging coil resistance (20°C/68°F) 0.1 – 1.0 Ω
ITEMSPECIFICATION
Bulbs Headlight 12 V - 60/55 W
Position light 12 V - 5 W
Brake/taillight 12 V - 21/5 W
Front turn signal light 12 V - 21 W x 2
Rear turn signal light 12 V - 21 W x 2
Instrument light LED
Turn signal indicator LED
High beam indicator LED
Neutral indicator LED
MIL LED
Fuse Main fuse 30 A
Sub fuse 10 A x 5, 5 A x 1
FASTENER TYPETORQUE
FASTENER TYPE TORQUE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)
6 mm bolt and nut
(Include SH flange bolt) 10 (1.0, 7) 6 mm screw
9.0 (0.9, 6.6)
6 mm flange bolt (8 mm head, large 
flange) and nut 12 (1.2, 9)
8 mm bolt and nut 22 (2.2, 16)
10 mm bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)
12 mm bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29) 
						

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GENERAL INFORMATIONENGINE & FRAME TORQUE VALUES
 • Torque specifications listed below are for important fasteners.
 • Others should be tightened to st andard torque values listed above.
FRAME/BODY PANELS/EXHAUST SYSTEM
MAINTENANCE
PGM-FI SYSTEM ITEM QTY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Hook bolt 4 8 21 (2.1, 15)
Left side cover assembly  screw 2 4 0.9 (0.1, 0.7)
Right fuel tank shroud assembly screw 4 4 0.9 (0.1, 0.7)
Left fuel tank shroud assembly screw 2 4 0.9 (0.1, 0.7)
Headlight cowl mounting bolt 4 6 8.5 (0.9, 6.3)
Rear side reflector mounting nut (U type 
only) 2 6 1.5 (0.2, 1.1) U-nut
Rear reflector mounting nut 1 5 1.5 (0.2, 1.1) U-nut
Brake/taillight mounting screw 3 6 4.5 (0.5, 3.3)
Exhaust pipe protector socket bolt 2 6 12 (1.2, 9)
Muffler protector cover screw 5 4 1.5 (0.2, 1.1)
Muffler front mounting bolt 1 8 32 (3.3, 24)
Muffler band bolt 1 8 22.5 (2.3, 17)
Exhaust pipe joint nut 2 8 18 (1.8, 13)
Exhaust pipe stud bolt 2 8 – See page 2-11
Air cleaner connecting hose band screw 1 4 1.5 (0.2, 1.1)
Sub-frame upper mounting nut 2 8 27 (2.8, 20)
Sub-frame lower mounting bolt 2 8 27 (2.8, 20)
Rear master cylinder reservoir mounting 
bolt 1 6 10 (1.0, 7)
Sidestand pivot bolt 1 10 10 (1.0, 7) See page 2-14
Sidestand pivot lock nut 1 10 30 (3.1, 22) U-nut, See page 2-14
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Throttle cable A adjuster lock nut (throttle 
body side) 16 3.0 (0.3, 2.2)
Air cleaner cover screw 45 1.2 (0.1, 0.9)
Spark plug 1 1016 (1.6, 12)
Crankshaft hole cap 1 308.0 (0.8, 5.9) Apply engine oil to the 
threads.
Timing hole cap 1 146.0 (0.6, 4.4) Apply engine oil to the 
threads.
Engine oil drain bolt 1 1224 (2.4, 18)
Drive chain adjuster lock nut 28 27 (2.8, 20) UBS nut
Rear axle nut 1 1688 (9.0, 65) U-nut
Drive sprocket fixing plate bolt 26 10 (1.0, 7)
Driven sprocket nut 6 1050 (5.1, 37) U-nut
Rear master cylinder reservoir mounting 
bolt 1
6 10 (1.0, 7)
Master cylinder reservoir cover screw 4 41.5 (0.2, 1.1)
Rear master cylinder push rod lock nut 1 817.2 (1.8, 13)
Front spoke 36 BC 3.2 3.7 (0.4, 2.7)
Rear spoke 32 BC 3.2 3.7 (0.4, 2.7)
ITEMQTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Sensor unit torx screw 35 3.4 (0.3, 2.5)
ECT sensor 1 1225 (2.5, 18)
O
2 sensor 1 1225 (2.5, 18)
Bank angle sensor mounting nut 26 9.0 (0.9, 6.6) 
						

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GENERAL INFORMATION
IGNITION SYSTEM
ELECTRIC STARTER
FUEL SYSTEM
COOLING SYSTEM
CYLINDER HEAD/VALVES
CYLINDER/PISTONITEM QTY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Timing hole cap 1 14 6.0 (0.6, 4.4) Apply engine oil to the  threads.
ITEMQTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Negative brush screw 15 3.7 (0.4, 2.7)
Starter motor assembly bolt 25 4.9 (0.5, 3.6)
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Fuel pump mounting nut 66 12 (1.2, 9) For tightening sequence 
(page 7-9).
Air cleaner housing mounting bolt 36 7.0 (0.7, 5.2)
Insulator band screw 25 4.2 (0.4, 3.1) See page 7-13
Air cleaner connecting hose band screw 1 41.5 (0.2, 1.1)
Throttle cable stay screw 25 3.4 (0.3, 2.5)
Clamp stay screw 15 3.4 (0.3, 2.5)
Throttle cable A joint nut (grip side) 1 101.5 (0.2, 1.1)
Throttle cable B joint nut (grip side) 1 121.5 (0.2, 1.1)
Throttle cable B nut (throttl e body side) 1 63.0 (0.3, 2.2)
Injector joint mounting bolt 25 5.1 (0.5, 3.8)
IACV setting plate torx  screw 24 2.1 (0.2, 1.5)
PAIR check valve cover bolt 25 5.2 (0.5, 3.8)
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Water hose band screw 4– –See page 9-7
Fan motor shroud mounting bolt 36 8.5 (0.9, 6.3)
Fan motor screw 34 2.7 (0.3, 2.0)
Cooling fan nut 13 1.0 (0.1, 0.7) Apply locking agent to the 
threads.
Water pump impeller 17 10 (1.0, 7)
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cylinder head cover bolt 26 10 (1.0, 7)
Camshaft  holder  mounting  bolt 86 12  (1.2,  9) Apply engine oil to the threads 
and seating surface.
Cylinder head mounting nut 4 1045 (4.6, 33) Apply engine oil to the threads 
and seating surface.
Cam chain tensioner lifter plug 16 4.2 (0.4, 3.1)
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cylinder stud bolt 4 10–See page 11-4
Cam chain tensioner lifter plug 16 4.2 (0.4, 3.1) 
						

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GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE
ALTERNATOR/STARTER CLUTCH
CRANKCASE/CRANKSHAFT/T RANSMISSION/BALANCER
ENGINE REMOVAL/INSTALLATION ITEM QTY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Clutch center lock nut 1 16 108 (11.0, 80) Lock nut; replace with a new  one and stake.
Apply engine oil to the threads 
and seating surface.
Clutch lifter plate bolt 5 6 12 (1.2, 9)
Shift drum stopper plate bolt 1 6 10 (1.0, 7) Apply locking agent to the  threads.
Shift drum stopper arm bolt 1 6 10 (1.0, 7) Apply locking agent to the  threads.
Gearshift spindle return spring pin 1 8 30 (3.1, 22) Apply locking agent to the  threads.
Primary  drive  gear  lock  nut 1 16 108  (11.0,  80) Apply engine oil to the threads  and seating surface.
ITEMQTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Stator mounting socket bolt 36 10 (1.0, 7)
CKP sensor mounting socket bolt 26 10 (1.0, 7) Apply locking agent to the 
threads.
Coating width: 6.5 ± 1.0 mm 
(0.26 ± 0.04 in) from tip
Flywheel  bolt 1 12 128  (13.1,  94) Apply engine oil to the threads 
and seating surface.
Starter clutch socket bolt 68 30 (3.1, 22) Apply locking agent to the 
threads.
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Balancer  shaft  nut 1 1444  (4.5,  32) Apply engine oil to the threads 
and seating surface.
Cam chain tensioner pivot bolt 16 10 (1.0, 7) Apply locking agent to the 
threads.
Coating width: 6.5 ± 1.0 mm 
(0.26 ± 0.04 in) from tip
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear engine mounting nut 2 1045 (4.6, 33)
Front engine mounting nut 2 1055 (5.6, 41)
Engine hanger plate bolt 28 27 (2.8, 20)
Drive sprocket fixing plate bolt 26 10 (1.0, 7) 
						

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GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING
REAR WHEEL/SUSPENSIONITEM QTY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Front axle bolt 1 14 73.5 (7.5, 54)
Front axle pinch bolt 2 8 20 (2.0, 15)
Front brake disc bolt 6 6 20 (2.0, 15) ALOC bolt; replace with a new  one.
Front spoke 36 BC 3.2 3.7 (0.4, 2.7)
Top bridge pinch bolt 48 32 (3.3, 24)
Bottom bridge pinch bolt 48 32 (3.3, 24)
Front brake hose guide bolt 26 10 (1.0, 7)
Front brake hose clamp bolt 26 10 (1.0, 7)
Fork protector socket bolt 66 7.0 (0.7, 5.2) ALOC bolt; replace with a new 
one.
Front  brake  caliper  mounting  bolt 28 30  (3.1,  22) ALOC bolt; replace with a new 
one.
Fork center bolt 18 20 (2.0, 15) Apply locking agent to the 
threads.
Fork rod lock nut (Right side) 1 1020 (2.0, 15)
Fork inner damper rod lock nut (Left side) 1 10 20  (2.0,  15)
Fork cap 2 5035 (3.6, 26)
Handlebar switch housing screw 45 2.5 (0.3, 1.8)
Front master cylinder holder bolt 26 9.8 (1.0, 7.2)
Steering stem adjusting nut 1 26–Apply engine oil to the 
threads.
See page 16-24
Steering stem nut 1 24 103 (10.5, 76) See page 16-24
Clutch lever pivot bolt 16 1.0 (0.1, 0.7) Apply grease to the sliding 
surface.
Clutch lever pivot nut 16 5.9 (0.6, 4.4)
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear axle nut 1 1688 (9.0, 65) U-nut
Driven sprocket nut 6 1050 (5.1, 37) U-nut
Rear brake disc bolt 48 42 (4.3, 31) ALOC bolt; replace with a new 
one.
Rear spoke 32 BC 3.2 3.7 (0.4, 2.7)
Shock absorber upper mounting nut 1 1054 (5.5, 40) U-nut
Shock absorber lower mounting nut 1 1044 (4.5, 32) U-nut
Shock link nut 2 1044 (4.5, 32) U-nut
Shock arm-to-swingarm nut 1 1274 (7.5, 55) U-nut
Apply engine oil to the 
threads.
Swingarm pivot nut 1 1488 (9.0, 65) U-nut
Rear brake hose guide mounting screw 2 51.2 (0.1, 0.9)
Chain slider mounting screw 45 4.2 (0.4, 3.1) ALOC screw; replace with a 
new one.
Chain case stay mounting screw 16 4.2 (0.4, 3.1) ALOC screw; replace with a 
new one.
Chain guide mounting bolt 26 10 (1.0, 7) ALOC bolt; replace with a new 
one.
Chain slider guide mounting nut 26 2.5 (0.3, 1.8) U-nut 
						

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GENERAL INFORMATION
BRAKE SYSTEM
BATTERY/CHARGING SYSTEM
LIGHTS/METERS/SWITCHESITEM
QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Brake caliper bleed valve 28 5.4 (0.6, 4.0)
Master cylinder reservoir cover screw 4 41.5 (0.2, 1.1)
Rear master cylinder reservoir mounting 
bolt 1
6 10 (1.0, 7)
Front brake pad pin 1 1017.2 (1.8, 13)
Rear brake pad pin 1 1017.2 (1.8, 13)
Brake hose oil bolt 4 1034 (3.5, 25)
Front master cylinder holder bolt 26 9.8 (1.0, 7.2)
Front brake light switch screw 14 1.2 (0.1, 0.9)
Rear master cylinder mounting bolt 26 14 (1.4, 10) ALOC bolt; replace with a new 
one.
Rear master cylinder push rod lock nut 1 817.2 (1.8, 13)
Brake lever pivot bolt 16 1.0 (0.1, 0.7) Apply 0.1 g (0.004 oz) of 
silicone grease to the sliding 
surface.
Brake lever pivot nut 16 5.9 (0.6, 4.4)
Front  brake  caliper  mounting  bolt 28 30  (3.1,  22) ALOC bolt; replace with a new 
one.
Front brake caliper bracket pin 18 17.2 (1.8, 13)
Rear brake reservoir stay mounting 
screw 1
6 1.5 (0.2, 1.1)
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Battery holder plate bolt 26 7.0 (0.7, 5.2)
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Headlight unit mounting screw 45 1.2 (0.1, 0.9)
Turn signal unit mounting nut 4 1021 (2.1, 15)
Brake/taillight mounting screw 36 4.5 (0.5, 3.3)
Hook bolt 48 21 (2.1, 15)
Speedometer mounting screw 35 1.0 (0.1, 0.7)
Ignition switch mounting bolt 28 24 (2.4, 18) One-way bolt; replace with a 
new one.
Neutral switch 1 1012 (1.2, 9)
Sidestand  switch  mounting  bolt 16 10  (1.0,  7) ALOC bolt; replace with a new 
one. 
						

							1-15
dummyhead
dummyhead
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIALLOCATIONREMARKS
Liquid sealant (Three bond 
1207B, 1215 or equivalent) Left crankcase mating surface
See page 14-18
Alternator/CKP sensor wire grommet sealing surface
Liquid sealant (Three bond 
5211C, 1207B, 1215, SS 
KE45 or equivalent) Cylinder head semi-circular cut-out
Engine oil Oil pump rotor entire surface
Oil pump shaft outer surface
Water pump shaft outer surface
Cam chain whole surface
Cylinder inner surface
Piston pin hole inner surface,  ring groove and sliding 
surface
Piston ring entire surface
Clutch disc entire surface
Gearshift spindle shaft outer surface
Starter one-way clutch sprag
Starter driven gear sliding surface
Each oil seal lips
Each bearing rotating area
Each gear teeth
Each O-ring
Multi-purpose grease Each oil seal lips (clutch lifter arm, gearshift spindle, 
countershaft, water pump)
Molybdenum oil solution (a 
mixture of 1/2 engine oil and 
1/2 molybdenum disulfide 
grease) Valve stem sliding surface
Camshaft lobes and journal
Rocker arm shaft outer surface
Rocker arm inner surface, roller surface and slipper 
surface
Piston pin outer surface
Clutch outer guide whole surface
Clutch lifter arm sliding surface
Starter reduction gear inner surface
Starter reduction gear shaft outer surface
Crankshaft main journal 
bearing sliding surface
Connecting rod big end sliding surface
Connecting rod small end inner surface
Left crankshaft needle bearing rotating surface
Balancer driven gear and sub gear sliding surface
Shift fork inner surface and guide pin
Shift fork shaft outer surface
Shift drum journal outer surface and grooves
M5, C1, C2, C3 gear bushing entire surface
M6, C4 gear bushing outer surface
Locking agent Mainshaft bearing setting plate bolt threads Coating width: 6.5 ± 1.0 mm 
(0.26 ± 0.04 in) from tip