Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 3

 

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Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 3

 

 

CHASSIS SPECIFICATIONS

2-10

EAS20300

CHASSIS SPECIFICATIONS

Chassis

Frame type

Double cradle

Caster angle

31.20 °

Trail

152.0 mm (5.98 in)

Front wheel

Wheel type

Cast wheel

Rim size

18M/C 

×

 MT4.00

Rim material

Aluminum

Wheel travel

130.0 mm (5.12 in)

Radial wheel runout limit

1.0 mm (0.04 in)

Lateral wheel runout limit

0.5 mm (0.02 in)

Rear wheel

Wheel type

Cast wheel

Rim size

17M/C 

×

 MT5.50

Rim material

Aluminum

Wheel travel

110.0 mm (4.33 in)

Radial wheel runout limit

1.0 mm (0.04 in)

Lateral wheel runout limit

0.5 mm (0.02 in)

Front tire

Type

Tubeless

Size

130/70R18M/C 63H

Manufacturer/model

DUNLOP/D251F

Manufacturer/model

BRIDGESTONE/G851 RADIAL G

Wear limit (front)

1.0 mm (0.04 in)

Rear tire

Type

Tubeless

Size

190/60R17M/C 78H

Manufacturer/model

DUNLOP/D251

Manufacturer/model

BRIDGESTONE/G850 RADIAL G

Wear limit (rear)

1.0 mm (0.04 in)

Tire air pressure (measured on cold tires)

Loading condition

0–90 kg (0–198 lb)

Front

250 kPa (36 psi) (2.50 kgf/cm²)

Rear

280 kPa (41 psi) (2.80 kgf/cm²)

Loading condition

XV19S(C)/XV19(C)/XV19M(C):
90–210 kg (198–463 lb)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
90–186 kg (198–410 lb) 

Front

250 kPa (36 psi) (2.50 kgf/cm²)

Rear

280 kPa (41 psi) (2.80 kgf/cm²)

High-speed riding

Front

250 kPa (36 psi) (2.50 kgf/cm²)

Rear

280 kPa (41 psi) (2.80 kgf/cm²)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

CHASSIS SPECIFICATIONS

2-11

Front brake

Type

Dual disc brake

Operation

Right hand operation

Front disc brake

Disc outside diameter 

×

 thickness

298.0 

×

 5.0 mm (11.73 

×

 0.20 in)

Brake disc thickness limit

4.5 mm (0.18 in)

Brake disc deflection limit

0.10 mm (0.0039 in)

Brake pad lining thickness (inner)

5.5 mm (0.22 in)

Limit

0.5 mm (0.02 in)

Brake pad lining thickness (outer)

5.5 mm (0.22 in)

Limit

0.5 mm (0.02 in)

Master cylinder inside diameter

14.00 mm (0.55 in)

Caliper cylinder inside diameter

27.00 mm (1.06 in)

Caliper cylinder inside diameter

30.23 mm (1.19 in)

Recommended fluid

DOT 4

Rear brake

Type

Single disc brake

Operation

Right foot operation

Brake pedal position

110.0 mm (4.33 in)

Rear disc brake

Disc outside diameter 

×

 thickness

320.0 

×

 6.0 mm (12.60 

×

 0.24 in)

Brake disc thickness limit

5.5 mm (0.22 in)

Brake disc deflection limit

0.15 mm (0.0059 in)

Brake pad lining thickness (inner)

5.8 mm (0.23 in)

Limit

0.8 mm (0.03 in)

Brake pad lining thickness (outer)

5.8 mm (0.23 in)

Limit

0.8 mm (0.03 in)

Master cylinder inside diameter

12.7 mm (0.50 in)

Caliper cylinder inside diameter

41.30 mm (1.63 in)

Recommended fluid

DOT 4

Steering

Steering bearing type

Taper roller bearing

Lock to lock angle (left)

35.0 °

Lock to lock angle (right)

35.0 °

Front suspension

Type

Telescopic fork

Spring/shock absorber type

Coil spring/oil damper

Front fork travel

130.0 mm (5.12 in)

Fork spring free length

273.9 mm (10.78 in)

Limit

268.4 mm (10.57 in)

Collar length

230.0 mm (9.06 in)

Installed length

268.9 mm (10.59 in)

Spring rate K1

10.0 N/mm (57.1 lb/in) (1.02 kgf/mm)

Spring stroke K1

0.0–30.0 mm (0.00–1.18 in)

Spring rate K2

12.0 N/mm (68.5 lb/in) (1.22 kgf/mm)

Spring stroke K2

30.0–130.0 mm (1.18–5.12 in)

Inner tube outer diameter

46.0 mm (1.81 in)

Inner tube bending limit

0.2 mm (0.01 in)

Optional spring available

No

-------------------------------------------------------------------------------------------------------------------------------------------------------------

CHASSIS SPECIFICATIONS

2-12

Recommended oil

Fork oil 10WT

Quantity

571.0 cm³ (19.31 US oz) (20.10 Imp.oz)

Level

124.0 mm (4.88 in)

Rear suspension

Type

Swingarm (link suspension)

Spring/shock absorber type

Coil spring/gas-oil damper

Rear shock absorber assembly travel

50.0 mm (1.97 in)

Spring free length

180.0 mm (7.09 in)

Limit

176.4 mm (6.94 in)

Installed length

XV19S(C)/XV19(C)/XV19M(C):
171.0 mm (6.73 in)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
165.0 mm (6.50 in) 

Spring rate K1

176.50 N/mm (1007.82 lb/in) (18.00 kgf/mm)

Spring stroke K1

0.0–50.0 mm (0.00–1.97 in)

Optional spring available

No

Enclosed gas/air pressure (STD)

0.98 MPa (139.4 psi) (9.8 kgf/cm²)

Spring preload adjusting positions

Installed spring length

Minimum

162.0 mm (6.38 in)

Standard

XV19S(C)/XV19(C)/XV19M(C):
171.0 mm (6.73 in)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
165.0 mm (6.50 in)

Maximum

171.0 mm (6.73 in)

Swingarm

Swingarm end free play limit (radial)

1.0 mm (0.04 in)

Swingarm end free play limit (axial)

1.0 mm (0.04 in)

Drive belt

Model/manufacturer

UBD-0732/GATES CORPORATION

Drive belt slack (on the sidestand)

7.5–13 mm (0.30–0.51 in)

Drive belt slack (on a suitable stand)

14–21 mm (0.55–0.83 in)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SPECIFICATIONS

2-13

EAS20310

ELECTRICAL SPECIFICATIONS

Voltage

System voltage

12 V

Ignition system

Ignition system

Transistorized coil ignition (digital)

Advancer type

Electrical

Ignition timing (B.T.D.C.)

10.0 °/900 r/min

Engine control unit

Model/manufacturer

F008T83271/MITSUBISHI

Ignition coil

Model/manufacturer

2JN/MORIC

Minimum ignition spark gap

6.0 mm (0.24 in)

Primary coil resistance

2.16–2.64 

Secondary coil resistance

8.64–12.96 k

Spark plug cap

Material

Resin

Resistance

10.0 k

AC magneto

Model/manufacturer

F4T38971/MITSUBISHI

Standard output

14.0 V 32.0 A 5000 r/min

Stator coil resistance

0.112–0.168 

Rectifier/regulator

Regulator type

Semi conductor-short circuit

Model/manufacturer

FH012AA/SHINDENGEN

No load regulated voltage

14.2–14.8 V

Rectifier capacity

50.0 A

Withstand voltage

40.0 V

Battery

Model

GT14B-4

Voltage, capacity

12 V, 12.0 Ah

Manufacturer

GS YUASA

Ten hour rate amperage

1.20 A

Headlight

Bulb type

Halogen bulb

Bulb voltage, wattage 

×

 quantity

Low beam headlight

12 V, 51.0 W 

×

 1

High beam headlight

12 V, 55.0 W 

×

 1

Tail/brake light

LED

Front turn signal/position light

12 V, 23 W/8.0 W 

×

 2

Rear turn signal light

12 V, 21.0 W 

×

 2

License plate light

12 V, 5.0 W

Meter lighting

LED

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SPECIFICATIONS

2-14

Indicator light

Neutral indicator light

LED

Turn signal indicator light

LED

High beam indicator light

LED

Fuel level warning light

LED

Engine trouble warning light

LED

Electric starting system

System type

Constant mesh

Starter motor

Model/manufacturer

1D7/MORIC

Power output

0.90 kW

Armature coil resistance

0.0081–0.0099 

Brush overall length

9.8 mm (0.39 in)

Limit

5.00 mm (0.20 in)

Brush spring force

7.36–11.04 N (26.49–39.74 oz) (750–1126 gf)

Commutator diameter

28.5 mm (1.12 in)

Limit

27.5 mm (1.08 in)

Mica undercut (depth)

1.50 mm (0.06 in)

Starter relay

Model/manufacturer

2768079-A/JIDECO

Amperage

180.0 A

Coil resistance

4.18–4.62 

Horn

Horn type

Eddy

Quantity

2 pcs

Model/manufacturer

YP-12/NIKKO

Maximum amperage

2.0 A

Coil resistance

0.94–0.98 

Performance

95–115 dB/2m

Turn signal relay

Relay type

Semi transistor

Model/manufacturer

FB246H/DENSO

Built-in, self-canceling device

Yes

Turn signal blinking frequency

75.0–95.0 cycles/min

Wattage

21(23) W 

×

 2 + LED 

×

 2

Fuel gauge

Model/manufacturer

1D7/YAMAHA

Sender unit resistance (full)

9–11 

Sender unit resistance (empty)

213–219 

Starting circuit cut-off relay

Model/manufacturer

G8R-30Y-V3/OMRON

Coil resistance

162–198 

Headlight relay

Model/manufacturer

ACM33211M05/MATSUSHITA

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SPECIFICATIONS

2-15

Fuel pump relay

Model/manufacturer

G8R-30Y-V3/OMRON

Coil resistance

162–198 

Thermo unit

Model/manufacturer

5PX/DENSO

Resistance at 100°C

898.4–1098.0 

Fuses

Main fuse

50.0 A

Headlight fuse

20.0 A

Taillight fuse

10.0 A

Signaling system fuse

10.0 A

Ignition fuse

25.0 A

Auxiliary DC connector fuse

3.0 A

ECU fuse

10.0 A

Fuel injection system fuse

15.0 A

Backup fuse

10.0 A

Reserve fuse

25.0 A

Reserve fuse

20.0 A

Reserve fuse

15.0 A

Reserve fuse

10.0 A

Reserve fuse

3.0 A

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TIGHTENING TORQUES

2-16

EAS20320

TIGHTENING TORQUES

EAS20330

GENERAL TIGHTENING TORQUE 
SPECIFICATIONS

This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch. 
Tightening torque specifications for special com-
ponents or assemblies are provided for each 
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified 
tightening torque is reached. Unless otherwise 
specified, tightening torque specifications re-
quire clean, dry threads. Components should be 
at room temperature.

A. Distance between flats
B. Outside thread diameter

A (nut) B (bolt)

General tightening 

torques

Nm

m·kg

ft·lb

10 mm

6 mm

6

0.6

4.3

12 mm

8 mm

15

1.5

11

14 mm

10 mm

30

3.0

22

17 mm

12 mm

55

5.5

40

19 mm

14 mm

85

8.5

61

22 mm

16 mm

130

13.0

94

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TIGHTENING TORQUES

2-17

EAS20340

ENGINE TIGHTENING TORQUES

Item

Thread 

size

Q’ty

Tightening torque

Remarks

Cylinder head nut

M12

8

60 Nm (6.0 m·kg, 43 ft·lb)

Cylinder head stud bolt (exhaust 
pipe)

M8

4

15 Nm (1.5 m·kg, 11 ft·lb)

Spark plug

M12

4

18 Nm (1.8 m·kg, 13 ft·lb)

Engine temperature sensor

1

20 Nm (2.0 m·kg, 14 ft·lb)

Rocker arm base bolt

M6

4

10 Nm (1.0 m·kg, 7.2 ft·lb)

Rocker arm base bolt

M8

8

24 Nm (2.4 m·kg, 17 ft·lb)

Cylinder head cover bolt

M6

28

10 Nm (1.0 m·kg, 7.2 ft·lb)

Connecting rod bolt (1st)

M8

4

15 Nm (1.5 m·kg, 11 ft·lb)

See 

NOTE.

Connecting rod bolt (final)

M8

4

Specified angle 125–135°

See 

NOTE.

Right balancer driven gear bolt

M10

1

40 Nm (4.0 m·kg, 29 ft·lb)

Left balancer drive gear bolt

M10

1

40 Nm (4.0 m·kg, 29 ft·lb)

Left balancer driven gear housing 
screw

M6

6

10 Nm (1.0 m·kg, 7.2 ft·lb)

Left balancer weight bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Left balancer idle gear shaft bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft driven gear bolt

M10

1

60 Nm (6.0 m·kg, 43 ft·lb)

Camshaft drive gear bolt

M10

1

60 Nm (6.0 m·kg, 43 ft·lb)

Front cylinder camshaft gear bolt

M10

1

40 Nm (4.0 m·kg, 29 ft·lb)

Locknut (rocker arm adjusting 
screw)

M7

4

20 Nm (2.0 m·kg, 14 ft·lb)

Valve lifter case bolt

M6

4

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil filter bolt

M18

1

70 Nm (7.0 m·kg, 50 ft·lb)

Oil filter cartridge

M20

1

17 Nm (1.7 m·kg, 12 ft·lb)

Oil pipe 1 union bolt

M10

2

21 Nm (2.1 m·kg, 15 ft·lb)

Oil pipe 1 union bolt

M8

1

18 Nm (1.8 m·kg, 13 ft·lb)

Oil filter bracket bolt

M6

4

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pipe bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil delivery pipe 2 bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Engine oil pump driven gear 
stopper bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pipe 3 bolt

M6

5

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pump bolt (crankcase)

M8

3

24 Nm (2.4 m·kg, 17 ft·lb)

E

M

M

E

E

LT

LT

E

E

E

LT

LT

LT

LT

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TIGHTENING TORQUES

2-18

Oil pipe 2 bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pipe 4 bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pump housing cover 1 screw 
(crankcase)

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Oil pump housing cover 2 screw 
(crankcase)

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Throttle body joint clamp screw

M5

2

3 Nm (0.3 m·kg, 2.2 ft·lb)

Pressure regulator bolt

M5

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Intake manifold assembly bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Fuel pipe bolt

M12

2

30 Nm (3.0 m·kg, 22 ft·lb)

Rear exhaust pipe joint nut

M8

2

20 Nm (2.0 m·kg, 14 ft·lb)

Rear exhaust pipe, rear exhaust 
pipe joint cover and rear exhaust 
pipe joint nut

M8

2

24 Nm (2.4 m·kg, 17 ft·lb)

Front exhaust pipe nut

M8

2

20 Nm (2.0 m·kg, 14 ft·lb)

Front exhaust pipe and rear ex-
haust pipe bolt

M8

1

20 Nm (2.0 m·kg, 14 ft·lb)

Rear exhaust pipe and muffler 
bolt

M8

1

20 Nm (2.0 m·kg, 14 ft·lb)

Locknut (EXUP cable)

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

EXUP valve pulley cover bolt

M6

1

7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear exhaust pipe joint cover bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Muffler and muffler bracket bolt

M8

3

29 Nm (2.9 m·kg, 21 ft·lb)

Muffler bracket and frame bolt

M10

2

53 Nm (5.3 m·kg, 38 ft·lb)

O

2

 sensor

M18

1

44 Nm (4.4 m·kg, 32 ft·lb)

Crankcase stud bolt

M12

8

See NOTE.

Crankcase bolt

M6

21

10 Nm (1.0 m·kg, 7.2 ft·lb)

Crankcase bolt

M8

3

24 Nm (2.4 m·kg, 17 ft·lb)

Oil baffle plate bolt (left crank-
case)

M6

6

10 Nm (1.0 m·kg, 7.2 ft·lb)

Crankcase stud bolt

M10

1

See NOTE.

Nozzle

M6

4

0.5 Nm (0.05 m·kg, 0.36 ft·lb)

Oil gallery screw

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Bearing housing bolt (torque lim-
iter)

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil gallery bolt

M8

4

20 Nm (2.0 m·kg, 14 ft·lb)

Engine oil drain bolt (crankcase)

M14

2

43 Nm (4.3 m·kg, 31 ft·lb)

Stator coil lead holder screw

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Crankshaft position sensor lead 
holder screw

M6

6

10 Nm (1.0 m·kg, 7.2 ft·lb)

Item

Thread 

size

Q’ty

Tightening torque

Remarks

LT

E

LT

E

LT

LT

LT

LT

LT

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TIGHTENING TORQUES

2-19

Clutch cover damper plate screw

M6

4

10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft cover bolt

M6

8

10 Nm (1.0 m·kg, 7.2 ft·lb)

Generator damper cover bolt

M5

3

5 Nm (0.5 m·kg, 3.6 ft·lb)

Engine oil filler plug

M20

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft sprocket cover plate 
bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil baffle plate bolt (right crank-
case)

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Clutch cover plate bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Generator cover bolt

M6

10

10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft sprocket cover bolt

M6

8

10 Nm (1.0 m·kg, 7.2 ft·lb)

Clutch cover bolt

M6

18

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil gallery bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Clutch damper cover plate bolt

M5

3

5 Nm (0.5 m·kg, 3.6 ft·lb)

Clutch damper cover bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Starter clutch bolt

M8

6

24 Nm (2.4 m·kg, 17 ft·lb)

Generator rotor bolt

M12

1

80 Nm (8.0 m·kg, 58 ft·lb)

Starter motor bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Primary drive gear bolt

M12

1

100 Nm (10.0 m·kg, 72 ft·lb)

Clutch boss nut

M20

1

105 Nm (10.5 m·kg, 75 ft·lb)

Stake

Clutch spring plate retainer bolt

M6

6

8 Nm (0.8 m·kg, 5.8 ft·lb)

Bleed screw (clutch release cylin-
der)

M8

1

6 Nm (0.6 m·kg, 4.3 ft·lb)

Clutch release cylinder bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Drive axle bearing retainer screw

M8

2

20 Nm (2.0 m·kg, 14 ft·lb)

Stake

Main axle bearing retainer screw

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Engine oil drain bolt (oil tank)

M14

1

43 Nm (4.3 m·kg, 31 ft·lb)

Transfer gear oil drain bolt

M8

1

18 Nm (1.8 m·kg, 13 ft·lb)

Middle drive gear nut

M22

1

140 Nm (14.0 m·kg, 100 ft·lb)

Stake

Transfer gear case oil pump as-
sembly nut

M10

1

40 Nm (4.0 m·kg, 29 ft·lb)

Transfer gear case oil pump as-
sembly bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pump housing screw (transfer 
gear case)

M5

2

4 Nm (0.4 m·kg, 2.9 ft·lb)

Transfer gear oil check bolt

M6

1

8 Nm (0.8 m·kg, 5.8 ft·lb)

Transfer gear case bolt

M10

4

50 Nm (5.0 m·kg, 36 ft·lb)

Item

Thread 

size

Q’ty

Tightening torque

Remarks

LT

LT

LT

LT

LT

LT

E

E

E

LT

E

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TIGHTENING TORQUES

2-20

NOTE:

• Tighten the connecting rod bolts to 15 Nm (1.5 m·kg, 11 ft·lb), and then tighten them further to reach 

the specified angle 125–135°.

• Install the crankcase stud bolts (M12) so that their installed length is 141.5 mm (5.57 in).
• Install the crankcase stud bolts (M10) so that their installed length is 70.5 mm (2.78 in).

Dipstick joint bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Drive pulley case bolt

M10

8

70 Nm (7.0 m·kg, 50 ft·lb)

Oil strainer bolt (oil tank)

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pipe 5 bolt

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Transfer gear case cover plate 
bolt

M6

3

5 Nm (0.5 m·kg, 3.6 ft·lb)

Transfer gear case cover bolt

M6

12

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil tank cover bolt

M6

15

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil tank bracket bolt

M8

2

28 Nm (2.8 m·kg, 20 ft·lb)

Shift shaft spring stopper bolt

M8

1

22 Nm (2.2 m·kg, 16 ft·lb)

Stopper lever bolt

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Crankshaft position sensor screw

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Neutral switch screw

M6

2

4 Nm (0.4 m·kg, 2.9 ft·lb)

Stator coil screw

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Neutral switch lead clamp screw

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Speed sensor bolt

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil cooler bolt

M6

1

7 Nm (0.7 m·kg, 5.1 ft·lb)

Oil cooler bracket bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Oil cooler hose bolt

M6

8

7 Nm (0.7 m·kg, 5.1 ft·lb)

Clutch hose union bolt

M10

2

30 Nm (3.0 m·kg, 22 ft·lb)

Clutch pipe union bolt

M10

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Clutch pipe holder bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Clutch pipe joint nut

M10

1

19 Nm (1.9 m·kg, 13 ft·lb)

Item

Thread 

size

Q’ty

Tightening torque

Remarks

LT

LT

LT

LT

LT

LT

LT

LT

LT

LT

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TIGHTENING TORQUES

2-21

Cylinder head tightening sequence:

3

1

2

4

A

B

3

1

2

4

A. Front cylinder
B. Rear cylinder

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TIGHTENING TORQUES

2-22

EAS20350

CHASSIS TIGHTENING TORQUES

Item

Thread 

size

Q’ty

Tightening torque

Remarks

Engine mounting bolt (left upper 
side)

M12

2

66 Nm (6.6 m·kg, 48 ft·lb)

Engine mounting bolt (right upper 
side)

M12

2

59 Nm (5.9 m·kg, 43 ft·lb)

Engine mounting nut (rear upper 
side)

M12

1

98 Nm (9.8 m·kg, 71 ft·lb)

Engine mounting spacer bolt

M18

1

18 Nm (1.8 m·kg, 13 ft·lb)

Engine bracket bolt (left upper 
side)

M10

2

53 Nm (5.3 m·kg, 38 ft·lb)

Engine bracket bolt (right upper 
side)

M10

2

53 Nm (5.3 m·kg, 38 ft·lb)

Engine bracket nut (rear upper 
side)

M10

2

53 Nm (5.3 m·kg, 38 ft·lb)

Engine mounting nut (front upper 
side)

M12

1

98 Nm (9.8 m·kg, 71 ft·lb)

Engine mounting nut (rear lower 
side)

M12

1

98 Nm (9.8 m·kg, 71 ft·lb)

Engine mounting nut (front lower 
side)

M12

1

105 Nm (10.5 m·kg, 75 ft·lb)

Engine bracket nut (front upper 
side)

M10

4

53 Nm (5.3 m·kg, 38 ft·lb)

Engine cross-member bracket 
bolt

M10

2

30 Nm (3.0 m·kg, 22 ft·lb)

Engine bracket nut (left rear low-
er side)

M10

3

58 Nm (5.8 m·kg, 42 ft·lb)

Engine bracket bolt (right rear 
lower side)

M10

2

53 Nm (5.3 m·kg, 38 ft·lb)

Transfer gear case bracket and 
transfer gear case bolt

M10

2

63 Nm (6.3 m·kg, 45 ft·lb)

Transfer gear case bracket and 
frame bolt

M10

2

53 Nm (5.3 m·kg, 38 ft·lb)

Cylinder-#1 ignition coil bolt

M6

4

7 Nm (0.7 m·kg, 5.1 ft·lb)

Cylinder-#2 ignition coil bolt

M6

4

7 Nm (0.7 m·kg, 5.1 ft·lb)

Lean angle sensor bolt

M4

2

2 Nm (0.2 m·kg, 1.4 ft·lb)

Horn bolt

M6

4

10 Nm (1.0 m·kg, 7.2 ft·lb)

ISC (idle speed control) unit bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

ISC (idle speed control) unit 
bracket bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Pivot shaft nut

M18

1

125 Nm (12.5 m·kg, 90 ft·lb)

Relay arm nut (relay arm and 
swingarm)

M12

1

59 Nm (5.9 m·kg, 43 ft·lb)

LT

E

LT

LT

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TIGHTENING TORQUES

2-23

Relay arm nut (relay arm and 
connecting arm)

M12

1

59 Nm (5.9 m·kg, 43 ft·lb)

Rear shock absorber assembly 
nut (rear side)

M10

1

40 Nm (4.0 m·kg, 29 ft·lb)

Rear shock absorber assembly 
nut (front side)

M12

1

59 Nm (5.9 m·kg, 43 ft·lb)

Upper drive belt cover bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Lower drive belt cover bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear brake hose guide bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Upper bracket pinch bolt

M6

4

10 Nm (1.0 m·kg, 7.2 ft·lb)

Headlight cover bolt

M6

4

7 Nm (0.7 m·kg, 5.1 ft·lb)

Headlight bracket and throttle ca-
ble guide bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Headlight body bolt

M6

3

7 Nm (0.7 m·kg, 5.1 ft·lb)

Steering stem nut

M28

1

115 Nm (11.5 m·kg, 85 ft·lb)

Upper handlebar holder bolt

M8

4

28 Nm (2.8 m·kg, 20 ft·lb)

Lower ring nut (initial tightening 
torque)

M30

1

52 Nm (5.2 m·kg, 37 ft·lb)

See 

NOTE.

Lower ring nut (final tightening 
torque)

M30

1

18 Nm (1.8 m·kg, 13 ft·lb)

See 

NOTE.

Hose guide and lower handlebar 
holder nut

M10

2

32 Nm (3.2 m·kg, 23 ft·lb)

Front brake master cylinder hold-
er bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Front brake hose union bolt (front 
brake master cylinder side)

M10

2

30 Nm (3.0 m·kg, 22 ft·lb)

Clutch master cylinder holder bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Grip end

M16

2

23 Nm (2.3 m·kg, 17 ft·lb)

Lower handlebar holder nut

M10

2

50 Nm (5.0 m·kg, 36 ft·lb)

Upper bracket cover bolt

M8

2

19 Nm (1.9 m·kg, 13 ft·lb)

Upper bracket cover bolt

M8

2

16 Nm (1.6 m·kg, 11 ft·lb)

Front brake hose guide and front 
brake hose guide bracket bolt

M6

4

10 Nm (1.0 m·kg, 7.2 ft·lb)

Front brake hose guide and lower 
bracket bolt

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Front brake hose joint bolt

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Bolt (lower bracket hole)

M8

2

16 Nm (1.6 m·kg, 11 ft·lb)

Front fender stay bolt

M6

4

7 Nm (0.7 m·kg, 5.1 ft·lb)

Front fender bolt

M8

6

16 Nm (1.6 m·kg, 11 ft·lb)

Fuel sender bolt

M5

4

4 Nm (0.4 m·kg, 2.9 ft·lb)

Item

Thread 

size

Q’ty

Tightening torque

Remarks

LT

LT

LT

LT

LT

LT

LT

LT

LT

LT

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TIGHTENING TORQUES

2-24

Fuel tank bracket bolt (front side) 

M8

2

16 Nm (1.6 m·kg, 11 ft·lb)

Fuel tank bracket nut (rear side) 

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Sub-fuel tank bolt

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Rider seat bracket bolt

M8

2

23 Nm (2.3 m·kg, 17 ft·lb)

Fuel tank and fuel tank bracket 
bolt (front side) 

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Fuel tank and fuel tank bracket 
bolt (rear side) 

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Meter cover bolt

M6

3

7 Nm (0.7 m·kg, 5.1 ft·lb)

Fuel pump bolt

M5

6

5 Nm (0.5 m·kg, 3.6 ft·lb)

Fuel return pipe holder bolt

M6

1

7 Nm (0.7 m·kg, 5.1 ft·lb)

Air filter case bracket bolt

M8

3

16 Nm (1.6 m·kg, 11 ft·lb)

Canister bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

For Cali-

fornia 

only

Front wheel axle

M18

1

72 Nm (7.2 m·kg, 52 ft·lb)

Front wheel axle pinch bolt

M8

1

23 Nm (2.3 m·kg, 17 ft·lb)

Rear wheel axle nut

M18

1

150 Nm (15.0 m·kg, 110 ft·lb)

Locknut (drive belt adjusting bolt)

M8

2

16 Nm (1.6 m·kg, 11 ft·lb)

Front brake caliper bolt

M10

4

40 Nm (4.0 m·kg, 29 ft·lb)

Front brake hose union bolt (front 
brake caliper side)

M10

2

32 Nm (3.2 m·kg, 23 ft·lb)

Rear brake caliper bolt

M10

2

27 Nm (2.7 m·kg, 19 ft·lb)

Front brake disc bolt

M6

12

23 Nm (2.3 m·kg, 17 ft·lb)

Rear brake disc bolt

M6

6

18 Nm (1.8 m·kg, 13 ft·lb)

Bleed screw (front brake caliper)

M8

2

6 Nm (0.6 m·kg, 4.3 ft·lb)

Bleed screw (rear brake caliper)

M7

1

6 Nm (0.6 m·kg, 4.3 ft·lb)

Rear wheel pulley nut

M12

5

95 Nm (9.5 m·kg, 68 ft·lb)

Left side cover and sub-fuel tank 
bracket bolt

M6

1

7 Nm (0.7 m·kg, 5.1 ft·lb)

Left side cover bolt

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Seat lock cable assembly bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Lead holder bracket bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Right side cover bolt

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Starter motor lead bolt (starter 
relay side)

M6

1

7 Nm (0.7 m·kg, 5.1 ft·lb)

Positive battery lead bolt (starter 
relay side)

M6

1

7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear fender bracket and frame 
bolt 

M10

4

40 Nm (4.0 m·kg, 29 ft·lb)

Item

Thread 

size

Q’ty

Tightening torque

Remarks

LT

LS

LT

LT

LT

LT

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TIGHTENING TORQUES

2-25

Rear fender bracket and frame 
bolt

M10

2

40 Nm (4.0 m·kg, 29 ft·lb)

Rear fender bracket and rear 
fender bolt

M8

4

23 Nm (2.3 m·kg, 17 ft·lb)

Passenger seat bolt

M8

2

16 Nm (1.6 m·kg, 11 ft·lb)

Rider seat bracket assembly and 
seat lock assembly bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Tool kit and battery box bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Pressure regulator bracket bolt

M6

2

13 Nm (1.3 m·kg, 9.4 ft·lb)

Cylinder-#1 ignition coil cover 
bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

Cylinder-#1 ignition coil bracket 
bolt

M6

2

7 Nm (0.7 m·kg, 5.1 ft·lb)

License plate bolt

M8

3

16 Nm (1.6 m·kg, 11 ft·lb)

Sidestand bolt

M10

2

63 Nm (6.3 m·kg, 45 ft·lb)

Rider footrest assembly bolt (left 
and right)

M10

4

48 Nm (4.8 m·kg, 35 ft·lb)

Passenger footrest bolt (left and 
right)

M10

4

48 Nm (4.8 m·kg, 35 ft·lb)

Rear brake master cylinder 
bracket and rear brake master 
cylinder bolt

M8

2

23 Nm (2.3 m·kg, 17 ft·lb)

Rear brake master cylinder 
bracket and frame bolt

M8

2

23 Nm (2.3 m·kg, 17 ft·lb)

Rear brake master cylinder cover 
bolt

M8

2

16 Nm (1.6 m·kg, 11 ft·lb)

Brake fluid reservoir and frame 
bolt

M6

1

7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear brake hose union bolt

M10

2

30 Nm (3.0 m·kg, 22 ft·lb)

Rear brake hose holder bolt

M6

1

7 Nm (0.7 m·kg, 5.1 ft·lb)

Shift pedal shaft bracket bolt

M8

2

16 Nm (1.6 m·kg, 11 ft·lb)

Locknut (shift rod)

M8

2

12 Nm (1.2 m·kg, 8.7 ft·lb)

Shift arm bolt

M6

1

12 Nm (1.2 m·kg, 8.7 ft·lb)

Shift pedal bolt (toe side)

M6

1

18 Nm (1.8 m·kg, 13 ft·lb)

Shift pedal bolt (heel side)

M6

1

13 Nm (1.3 m·kg, 9.4 ft·lb)

Lower bracket pinch bolt

M8

4

23 Nm (2.3 m·kg, 17 ft·lb)

Cap bolt

M43

2

23 Nm (2.3 m·kg, 17 ft·lb)

Damper rod assembly

M12

2

40 Nm (4.0 m·kg, 29 ft·lb)

Lower front fork cover bolt

M6

4

7 Nm (0.7 m·kg, 5.1 ft·lb)

Drive pulley nut

M22

1

140 Nm (14.0 m·kg, 100 ft·lb)

Stake

Drive pulley cover damper plate 
screw

M6

3

10 Nm (1.0 m·kg, 7.2 ft·lb)

Item

Thread 

size

Q’ty

Tightening torque

Remarks

LT

LT

LT

LT

LT

LT

LT

LT

-------------------------------------------------------------------------------------------------------------------------------------------------------------

 

 

 

 

 

 

 

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