VALVES AND GUIDES Valve/Tappet Clearance (intake/exhaust) 0.06 mm (cold engine) Valve Guide/Stem (intake) 0.06 mm Clearance (max) (exhaust) 0.08 mm Valve Spring Free Length (min) (intake) 38.2 mm (exhaust) 44.3 mm Valve Spring Tension @ 33.7 mm (intake) 7.7-8.9 kg (22.5-38.4 lb) Valve Spring Tension @ 38.4 mm (exhaust) CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min) (intake) 31.40 mm (exhaust) 31.13 mm Rocker Arm/Shaft Clearance (max) 0.1 mm Cylinder Head/Cover Distortion (max) 0.05 mm CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance (max) 0.1 mm Cylinder Bore 62.030-62.045 mm Piston Diameter 5 mm from Skirt End 61.9 mm (min) Bore x Stroke 62 x 49.5 mm Cylinder Trueness (max) 0.05 mm Piston Ring to Groove Clearance (max) 0.09 mm (1st/2nd) Piston Ring End Gap - Installed (min) () 0.5 mm Piston Pin Bore (max) 15.04 mm Piston Pin Outside Diameter (min) 14.96 mm CRANKSHAFT Connecting Rod (small end inside 15.06 mm diameter) (max) Connecting Rod (big end side-to-side) 0.55 mm (max) Crankshaft Runout (max) 0.1 mm Oil Pressure at 60°C (140°F) (above) 0.3 kg/cm² (4.3 psi) @ 3000 RPM (below) 0.7 kg/cm² (10 psi) TRANSMISSION Clutch Wheel Inside Diameter (max) 130.5 mm Centrifugal Clutch Shoe Lining Thickness 2.0 mm Clutch Engagement RPM 3250 Clutch Lock-Up RPM 4700 Movable Drive Face Bushing I.D. (max) 27.06 mm Drive Face Collar (min) 26.94 mm Drive Belt Width (min) 19.0 mm Drive Pulley Weight Rollers (min) 20.42 mm Movable Driven Face Spring Free Length 83.20 mm (min) Fixed Driven Face Hub O.D. (min) 33.94 mm Movable Driven Face Bushing I.D. (max) 34.06 mm
Part
EXHAUST COMPONENTS Frame Cylinder head STEERING COMPONENTS Handlebar Clamp Cap Screw Steering Head Steering Post Support Block Frame Steering Post Nut Steering Post Steering Knuckle A-Arm Tie Rod End Nut Steering Arm Tie Rod End Nut Steering Knuckle Tie Rod Lock Nut Tie Rod BRAKE COMPONENTS Brake Hose Union Bolt Master Cylinder Brake Bleed Screw Caliper Exhaust Pipe Exhaust Pipe
Torque Specifications Part
Part Bolted To
DRIVE TRAIN COMPONENTS Engine Mounting Through-Bolt/ Frame Bracket Cap Screw Wheel Lug Nut Hub Hub Nut Axle Rear Axle Nut* Axle ELECTRICAL COMPONENTS Starter Motor Lead Nut Starter Starter Motor Mounting Cap Screw
Crankcase
Part Bolted To
Torque ft-lb N-m 29
39
40 50 86
54 68 117
Torque ft-lb N-m 25 7.2
34 10
15 15 50 32 32 32 22
20 20 68 44 44 44 30
25 51.5 in.-lb Master Cylinder Handlebar 9 Brake Pad Alignment Pin (Rear) Brake Caliper 13 Brake Caliper** (Rear) Swing Arm Housing 24 ENGINE/TRANSMISSION Cylinder Head Nut Cylinder 14 Engine Oil Drain Plug Crankcase 18 Cylinder Head Cap Screw Crankcase 7 Rotor/Flywheel Nut Crankshaft 40 Drive Sprocket Lock Plate Driveshaft 40 Crankcase Cap Screw Crankcase 7 Engine Oil Screen/Filter Cap Crankcase 11 Shift Detent Bolt Transmission Case 35 Camshaft Chain Tensioner Cover Cam Chain 36 Bolt Tensioner in.-lb Camshaft Chain Tensioner Mount Cylinder Head 9 Centrifugal Clutch Housing* Driveshaft 40 Driven Pulley Retaining Nut Driven Shaft 43 (Transmission) Drive Plate Nut* Fixed Drive Face 43 Drive Pulley Nut Crankshaft 43 Transmission Drain Plug Transmission 21 Balancer Nut* Balancer Shaft 32 Oil Pump Crankcase 7 Oil Pump Baffle Crankcase 7 Oil Pump Driven Gear* Oil Pump 7 Starter One-Way Drive Nut* Crankshaft 68 Magneto Cover Crankcase 7 Outer Magneto Cover Magneto Cover 7 CVT Cover Cap Screw Crankcase 7 SUSPENSION COMPONENTS (Front) A-Arm Pivot Nut Frame 32 Front Shock Absorber Mounting Nut* Frame/A-Arm 29 (Upper/Lower) SUSPENSION COMPONENTS (Rear) Swing Arm Pivot Nut Frame 50 Rear Shock Absorber Mounting Nut Frame/Swing Arm 29 (Upper/Lower) Axle Housing Cap Screw Swing Arm 50
34 6 12 18 33 19 25 10 55 55 10 15 48 4 12 54 59 59 59 29 45 10 10 10 92 10 10 10 44 39
68 39 68
* w/Red Loctite #271 ** w/Blue Loctite #242
36 5 in.-lb 7 10
3
