Yamaha XV1700P, XV1700PC. Service Manual - part 5

2 - 10

SPEC

ENGINE SPECIFICATIONS

2nd ring

Ring type

Taper

----

Dimensions (B 

×

 T)

1.2 

×

 3.8 mm (0.047 

×

 0.150 in)

----

End gap (installed)

0.30 ~ 0.45 mm (0.012 ~ 0.018 in)

0.8 mm 
(0.031 in)

Ring side clearance

0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in)

0.12 mm 
(0.0047 in)

Plating/coating

Parkerizing

----

Oil ring

Dimensions (B 

×

 T)

2.5 

×

 3.4 mm (0.098 

×

 0.134 in)

----

End gap (installed)

0.2 ~ 0.7 mm (0.008 ~ 0.028 in)

----

Plating/coating

Chrome plated/parkerizing

----

Connecting rods

Crankshaft pin-to-big end bearing 
clearance

0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in)

----

Bearing color code 

1 = Blue, 2 = Black, 3 = Brown, 4 = Green,
5 = Yellow.

----

Connecting rod length

191.95 ~ 192.05 mm (7.557 ~ 7.561 in)

----

Crankshaft

Width A

132.8 ~ 133.2 mm (5.228 ~ 5.244 in)

----

Max. runout C

----

0.04 mm 
(0.0016 in)

Big end side clearance D

0.320 ~ 0.474 mm (0.0126 ~ 0.0187 in)

----

Big end radial clearance E

0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in)

0.09 mm 
(0.0035 in)

Crankshaft journal-to-crankshaft-
journal bearing clearance

0.030 ~ 0.060 mm (0.0012 ~ 0.0024 in)

0.1 mm 
(0.0039 in)

Item

Standard

Limit

B

T

B

T

A

D

C

C

E

2 - 11

SPEC

ENGINE SPECIFICATIONS

Clutch

Clutch type

Wet, multiple disc

----

Clutch release method

Outer pull, rack and pinion (pull rod type)

----

Clutch release method operation

Cable operation

----

Operation

Left-hand operation

----

Clutch cable free play (at the end of 
the clutch lever)

10 ~ 15 mm (0.39 ~ 0.59 in)

----

Friction plates

Thickness

2.9 ~ 3.1 mm (0.114 ~ 0.122 in)

2.8 mm 
(0.110 in)

Plate quantity

9

----

Clutch plates 

Thickness

2.2 ~ 2.4 mm (0.087 ~ 0.094 in)

----

Plate quantity

8

----

Max. warpage

----

0.2 mm 
(0.008 in)

Clutch springs

Free length

7 mm (0.276 in)

----

Spring quantity

1

----

Min. length

----

6.5 mm 
(0.256 in)

Clutch housing thrust clearance

0.10 ~ 0.37 mm (0.0039 ~ 0.0146 in)

----

Clutch housing radial clearance

0.017 ~ 0.053 mm (0.0007 ~ 0.0021 in)

----

Primary reduction gear backlash tol-
erance

A-A, B-B, C-C, D-D, E-E

----

Primary drive gear backlash Number

A, B, C, D, E, F

----

Primary driven gear backlash Num-
ber

A, B, C, D, E, F

----

Item

Standard

Limit

2 - 12

SPEC

ENGINE SPECIFICATIONS

Transmission

Transmission type

Constant mesh, 5-speed

----

Primary reduction system

Spur gear

----

Primary reduction ratio

72/47 (1.532)

----

Secondary reduction system

Belt drive

----

Secondary reduction ratio

35/32 

×

 70/32 (2.393)

----

Operation

Left-foot operation

----

Gear ratios

1st gear

38/16 (2.375)

----

2nd gear

30/19 (1.579)

----

3rd gear

29/25 (1.160)

----

4th gear

29/31 (0.935)

----

5th gear

24/30 (0.800)

----

Max. main axle runout

----

0.08 mm 
(0.003 in)

Max. drive axle runout

----

0.08 mm 
(0.003 in)

Shifting mechanism

Shift mechanism type

Guide bar

----

Max. shift fork guide bar bending 

----

0.025 mm 
(0.001 in)

Shift fork thickness

6.26 ~ 6.39 mm (0.2465 ~ 0.2516 in)

----

Air filter type

Wet element

----

Fuel pump

Pump type

Electrical

----

Model (manufacturer)

5PX (MITSUBISHI)

----

Output pressure

392 ~ 588 kPa 
(3.92 ~ 5.88 kg/cm

2

, 55.7 ~ 83.6 psi)

----

Throttle bodies

Model (manufacturer) 

×

 quantity

AC40-B204 (MIKUNI) 

×

 2

----

Throttle cable free play (at the flange 
of the throttle grip)

4 ~ 6 mm (0.16 ~ 0.24 in)

----

ID mark

XV1700PC 5PX1 00 (USA and CAN)
XV1700PC 5PX2 10 (California)

----
----

Throttle valve size

#100

----

Item

Standard

Limit

2 - 13

SPEC

CHASSIS SPECIFICATIONS

CHASSIS SPECIFICATIONS

Item

Standard

Limit

Frame

Frame type

Double cradle

----

Caster angle

29.5°

----

Trail

130 mm (5.12 in)

----

Front wheel

Wheel type

Cast wheel

----

Rim

Size

18 M/C 

×

 MT 3.50

18 

×

 MT 3.50

----

Material

Aluminum

----

Wheel travel

135 mm (5.31 in)

----

Wheel runout 

Max. radial wheel runout

----

1 mm 
(0.04 in)

Max. lateral wheel runout

----

0.5 mm 
(0.02 in)

Rear wheel

Wheel type

Cast wheel

----

Rim 

Size

17 M/C 

×

 MT 6.00

17 

×

 MT 6.00

----

Material

Aluminum

----

Wheel travel

110 mm (4.33 in)

----

Wheel runout

Max. radial wheel runout

----

1 mm 
(0.04 in)

Max. lateral wheel runout

----

0.5 mm 
(0.02 in)

Front tire

Tire type

Tubeless

----

Size

120/70 ZR 18 M/C (59 W)
120/70 ZR 18 (59 W)

----

Model (manufacturer)

D220FST (DUNLOP)/
BT020FG (BRIDGESTONE)

----

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lb)

250 kPa (2.5 kgf/cm

2

, 36 psi)

----

90 kg (198 lb) ~ Maximum load*

250 kPa (2.5 kgf/cm

2

, 36 psi)

----

High-speed riding

250 kPa (2.5 kgf/cm

2

, 36 psi)

----

* Load is the total weight of the cargo,

rider, passenger and accessories.

Min. tire tread depth

----

1.0 mm 
(0.04 in)

2 - 14

SPEC

CHASSIS SPECIFICATIONS

Rear tire

Tire type

Tubeless

----

Size

200/50 ZR 17 M/C (75 W)
200/50 ZR 17 (75 W)

----

Model (manufacturer)

D220ST (DUNLOP)/
BT020R (BRIDGESTONE)

----

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lb)

250 kPa (2.5 kgf/cm

2

, 36 psi)

----

90 kg (198 lb) ~ Maximum load*

290 kPa (2.9 kgf/cm

2

, 42 psi)

----

High-speed riding

250 kPa (2.5 kgf/cm

2

, 36 psi)

----

* Load is the total weight of the cargo,

rider, passenger and accessories.

Min. tire tread depth

----

1.0 mm 
(0.04 in)

Front brakes

Brake type

Dual-disc brake

----

Operation

Right-hand operation

----

Brake lever free play (lever end)

2 ~ 5 mm (0.08 ~ 0.20 in)

----

Recommended fluid

DOT 4

----

Brake discs

Diameter 

×

 thickness

298 

×

 5 mm (11.73 

×

 0.20 in)

----

Min. thickness 

----

4.5 mm 
(0.18 in)

Max. deflection 

----

0.1 mm 
(0.004 in)

Brake pad lining thickness

5.5 mm (0.22 in)

0.5 mm 
(0.02 in)

Master cylinder inside diameter

14 mm (0.55 in)

----

Caliper cylinder inside diameter

27 mm (1.06 in) and 30.2 mm (1.19 in)

----

Item

Standard

Limit

2 - 15

SPEC

CHASSIS SPECIFICATIONS

Rear brake

Brake type

Single-disc brake

----

Operation

Right-foot operation

----

Brake pedal free play (P)

0 mm (0 in)

----

Brake pedal position 
(from the top of the rider footrest to
the top of the brake pedal)

80 mm (3.2 in)

----

Recommended fluid

DOT 4

----

Brake discs

Diameter 

×

 thickness

282 

×

 6 mm (11.10 

×

 0.24 in)

----

Min. thickness

----

5.5 mm 
(0.22 in)

Max. deflection 

----

0.15 mm 
(0.006 in)

Brake pad lining thickness

5.8 mm (0.23 in)

0.8 mm 
(0.03 in)

Master cylinder inside diameter

12.7 mm (0.5 in)

----

Caliper cylinder inside diameter

41.3 mm (1.63 in)

----

Steering

Steering bearing type

Taper roller bearings

----

Lock to Lock angle (left)

35°

----

Lock to Lock angle (right)

35°

----

Front suspension

Suspension type

Telescopic fork

----

Front fork type

Coil spring/oil damper

----

Front fork travel

135 mm (5.31 in)

----

Spring

Free length

296 mm (11.65 in)

291 mm 
(11.46 in)

Spring rate (K1)

6.4 N/mm (0.64 kg/mm, 36.54 lb/in)

----

Spring rate (K2)

7.8 N/mm (0.78 kg/mm, 44.54 lb/in)

----

Spring stroke (K1)

0 ~ 85 mm (0 ~ 3.35 in)

----

Spring stroke (K2)

85 ~ 135 mm (3.35 ~ 5.31 in)

----

Optional spring available

No

----

Fork oil

Recommended oil

Suspension oil “01”

----

Quantity (each front fork leg)

476 cm

3

 (16.8 Imp oz, 16.1 US oz)

----

Level (from the top of the outer 
tube and damper rod, with the outer 
tube fully compressed, and without 
the fork spring)

100 mm (3.94 in)

----

Inner tube outer diameter

41 mm (1.61 in)

----

Item

Standard

Limit

2 - 16

SPEC

CHASSIS SPECIFICATIONS

Rear suspension

Suspension type

Swingarm (link suspension)

----

Rear shock absorber assembly type

Coil spring/gas-oil damper

----

Rear shock absorber assembly travel 50 mm (1.97 in)

----

Spring

Free length

188 mm (7.4 in)

183 mm 
(7.2 in)

Installed length

172 mm (6.77 in)

----

Spring rate (K1)

137 N/mm (13.7 kg/mm, 782.27 lb/in)

----

Spring stroke (K1)

0 ~ 50 mm (0 ~ 1.97 in)

----

Optional spring available

No

----

Standard spring preload gas/air pres-
sure 

1,000 kPa (10 kg/cm

2

, 142 psi)

----

Swingarm

Free play (at the end of the swin-
garm)

Radial

----

1 mm 
(0.04 in)

Axial

----

1 mm 
(0.04 in)

Drive belt

Model (manufacturer)

UBD-0568

----

Drive belt slack (on a sidestand)

6 ~ 8 mm (0.24 ~ 0.31 in)

----

Drive belt slack (on a suitable stand)

7 ~ 9 mm (0.28 ~ 0.35 in)

----

Item

Standard

Limit

2 - 17

SPEC

ELECTRICAL SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

Item

Standard

Limit

System voltage

12 V

----

Ignition system

Ignition system type

Transistorized coil ignition (digital)

----

Ignition timing

10° BTDC at 900 r/min

----

Advancer type

Electric

----

Crankshaft position sensor 
resistance/color

248 ~ 372 

Ω

/Gy–B

----

Transistorized coil ignition unit model
(manufacturer)

F8T914 (MITSUBISHI)

----

Ignition coils

----

Model (manufacturer)

J0447 (DENSO)

----

Minimum ignition spark gap

6 mm (0.24 in)

----

Primary coil resistance

1.31 ~ 1.79 

Ω

 ----

Secondary coil resistance

12 ~ 18 k

Ω

 ----

Spark plug caps

Material

Resin

----

Resistance

10 k

Ω

 ----

Charging system

System type

AC magneto

----

Model (manufacturer)

F5PX/YAMAHA

----

Nominal output

14 V/31 A at 5,000 r/min

----

Stator coil resistance/color

0.12 ~ 0.20 

Ω

/W–W

----

Rectifier/regulator

Regulator type

Semiconductor, short circuit

----

Model (manufacturer)

FH001 (SHINDENGEN)

----

No-load regulated voltage

14.1 ~ 14.9 V

----

Rectifier capacity

35 A

----

Withstand voltage

200 V

----

Battery

Battery type (manufacturer)

GT14B-4 (GS)

----

Battery voltage/capacity

12 V/12 AH

----

Specific gravity

1.320

----

Ten hour rate amperage

1.2 A

----

Headlight type

Halogen bulb

----

Indicator light 
(voltage/wattage 

×

 quantity)

Meter light

LED 

×

 13

----

Neutral indicator light

LED 

×

 1

----

Turn signal indicator light

LED 

×

 2

----

Fuel indicator light

LED 

×

 1

----

High beam indicator light

LED 

×

 1

----

Engine trouble warning light

LED 

×

 1

----

2 - 18

SPEC

ELECTRICAL SPECIFICATIONS

Bulbs (voltage/wattage 

×

 quantity)

Headlight

12 V 60 W/55 W 

×

 1

----

Licence plate light

12 V 5 W 

× 

2

----

Tail/brake light

LED

----

Front turn signal/position light

12 V 23 W/8 W 

×

 2

----

Rear turn signal light 

12 V 23 W 

×

 2

----

Speedometer light

LED 

×

 1

----

Tachometer light

LED 

×

 1

----

Electric starting system

System type

Constant mesh

----

Starter motor

Model (manufacturer)

5PX (YAMAHA)

----

Power output

0.9 kW

----

Armature coil resistance

0.0081 ~ 0.0099 

Ω

----

Brushes

Overall length

9.8 mm (0.39 in)

5 mm 
(0.2 in)

Spring force

7.36 ~ 11.04 N (736 ~ 1,104 g)

----

Commutator diameter

28.5 mm (1.12 in)

27.5 mm 
(1.08 in)

Mica undercut

1.5 mm (0.06 in)

----

Starter relay

Model (manufacturer)

MS5F-631 (JIDECO)

----

Amperage

180 A

----

Coil resistance

4.18 ~ 4.62 

Ω

 ----

Starting circuit cut-off relay

Model/manufacturer

G8R-30Y-S/OMRON

----

Coil resistance

162 ~ 198 

Ω

----

Horn

Horn type

Eddy

----

Model (manufacturer) 

×

 quantity

YP-12 (NIKKO) 

×

 2

----

Max. amperage

2 A

----

Performance

95 ~ 115 db/2 m

----

Coil resistance

0.94 ~ 0.98 

Ω

----

Turn signal relay

Relay type

Semi-transistor

----

Model (manufacturer)

FB257H (DENSO)

----

Self-cancelling device built-in

Yes

----

Hazard flasher device

Yes

----

Turn signal blinking frequency

75 ~ 95 cycles/min.

----

Wattage

23 W 

×

 2 + 3.4 W

----

Item

Standard

Limit

2 - 19

SPEC

ELECTRICAL SPECIFICATIONS

Headlight relay

Model/manufacturer

ACM33211 M04/MATSUSHITA

----

Coil resistance

86.4 ~ 105.6 

Ω

----

Fuel injection system relay

Model/manufacturer

G8R-30Y-S/OMRON

----

Coil resistance

162 ~ 198 

Ω

----

Throttle position sensor

Resistance

4 ~ 6 k

Ω

/L-B

----

Output voltage (at idle)

0.605 ~ 0.755 V

----

Circuit breaker

Circuit breaker type

Fuse

----

Fuses (amperage 

×

 quantity)

Main fuse

30 A 

×

 1

----

Fuel injection system fuse

15 A 

×

 1

----

Headlight fuse

15 A 

×

 1

----

Signaling system fuse

10 A 

×

 1

----

Ignition fuse

10 A 

×

 1

----

ECU fuse

10 A 

×

 1

----

Decompression solenoid fuse

15 A 

×

 1

----

Backup fuse (odometer and clock)

7.5 A 

×

 1

----

Reserve fuse

30 A, 15 A, 10 A, 7.5 A 

×

 1

----

Engine temperature sensor

Model/manufacturer

5PX/DENSO

----

Resistance

895.38 ~ 1,098.02 

Ω

 at 100 °C (212 °F)

----

Item

Standard

Limit

2 - 20

SPEC

EAS00028

CONVERSION TABLE

All specification data in this manual are listed
in SI and METRIC UNITS. 
Use this table to convert METRIC unit data to
IMPERIAL unit data.

CONVERSION TABLE

EAS00030

GENERAL TIGHTENING TORQUE 
SPECIFICATIONS

This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Com-
ponents should be at room temperature.

A: Distance between flats
B: Outside thread diameter

Ex.

METRIC

MULTIPLIER

IMPERIAL

** mm

0.03937

** in

2 mm

0.03937

0.08 in

METRIC TO IMPERIAL

Tighten-
ing torque

Metric unit

Multiplier

Imperial unit

m·kg
m·kg
cm·kg
cm·kg

7.233
86.794
0.0723
0.8679

ft·lb
in·lb
ft·lb
in·lb

Weight

kg
g

2.205
0.03527

lb
oz

Speed

km/hr

0.6214

mph

Distance

km
m
m
cm
mm

0.6214
3.281
1.094
0.3937
0.03937

mi
ft
yd
in
in

Volume/
Capacity

cc (cm

3

)

cc (cm

3

)

lt (liter)
lt (liter)

0.03527
0.06102
0.8799
0.2199

oz (IMP lip.)
cu.in
qt (IMP liq.)
gal (IMP liq.)

Misc.

kg/mm
kg/cm

2

Centigrade 
(°C)

55.997
14.2234
9/5+32

lb/in
psi (lb/in

2

)

Fahrenheit (°F)

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

CONVERSION TABLE/

GENERAL TIGHTENING TORQUE SPECIFICATIONS

2 - 21

SPEC

TIGHTENING TORQUES

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

Item

Fastener

Thread 

size

Q’ty

Tightening torque

Remarks

Nm

m·kg

ft·lb

Spark plug

—

M12

4

18

1.8

13

Front cylinder head cover

Bolt

M6

14

10

1.0

7.2

Rear cylinder head cover

Bolt

M6

14

10

1.0

7.2

Front rocker arm base

Bolt

M8

2

24

2.4

17

Front rocker arm base

Bolt

M6

4

10

1.0

7.2

Rear rocker arm base

Bolt

M8

2

24

2.4

17

Rear rocker arm base

Bolt

M6

4

10

1.0

7.2

Cylinder head

Nut

M12

8

60

6.0

43

E

Cylinder head

Nut

M10

4

39

3.9

28

E

Engine temperature sensor

—

M12

1

20

2.0

14

See NOTE *1.

Cylinder head (exhaust pipe)

Stud bolt 

M8

4

15

1.5

11

Camshaft driven gear

Nut

M14

1

52

5.2

37

Camshaft driven gear

Bolt

M10

1

30

3.0

22

Camshaft cover

Bolt

M6

6

10

1.0

7.2

Decompression solenoid

Bolt

M4

2

7

0.7

5.1

Camshaft sprocket cover 1

Bolt

M6

2

7

0.7

5.1

Camshaft sprocket cover 1

Bolt

M6

1

10

1.0

7.2

Camshaft sprocket cover 2

Bolt

M6

5

10

1.0

7.2

Engine left side cover

Bolt

M6

6

10

1.0

7.2

Rocker arm adjusting screw

Nut

M7

4

20

2.0

14

Valve lifter case

Bolt

M6

4

10

1.0

7.2

Engine oil checking bolt

Bolt

M5

3

4

0.4

2.9

Front cylinder camshaft end cover

Bolt

M5

2

5

0.5

3.6

Engine oil drain bolt (crankcase)

—

M14

1

43

4.3

31

Engine oil drain bolt (oil tank)

—

M14

1

43

4.3

31

Oil filter cartridge

—

M20

1

17

1.7

12

E

Oil filter bolt

Union bolt

M20

1

70

7.0

50

Oil filter bracket

Bolt

M6

4

10

1.0

7.2

Oil delivery pipe

Bolt

M6

4

10

1.0

7.2

Oil delivery pipe 
(cylinder head-to-crankcase) 

Union bolt

M10

2

21

2.1

15

Oil delivery pipe 
(cylinder head-to-crankcase) 

Union bolt

M8

1

18

1.8

13

Oil strainer

Bolt

M6

2

10

1.0

7.2

Engine oil pump assembly

Bolt

M6

3

10

1.0

7.2

Oil pump housing cover

Screw

M4

4

2

0.2

1.4

Dipstick

—

M33

1

2

0.2

1.4

2 - 22

SPEC

TIGHTENING TORQUES

Intake manifold

Bolt

M6

4

10

1.0

7.2

Throttle body joint

Screw

M4

2

4

0.4

2.9

Pressure regulator

Bolt

M5

2

7

0.7

5.1

Intake vacuum hose bracket

Bolt

M6

1

10

1.0

7.2

Intake air pressure sensor bracket 2

Bolt

M6

1

10

1.0

7.2

A.I.S. bracket

Bolt

M5

4

4

0.4

2.9

Resonator

Screw

M5

2

2

0.2

1.4

Air cut-off valve assembly 

Bolt

M8

1

24

2.4

17

Air cut-off valve assembly 

Bolt

M6

2

10

1.0

7.2

Air filter case

Bolt

M6

2

7

0.7

5.1

Air filter case clamp

Screw

M4

1

3

0.3

2.2

Front exhaust pipe

Nut

M8

2

20

2.0

14

Rear exhaust pipe

Bolt

M8

2

24

2.4

17

Rear exhaust pipe joint cover

Screw

M6

2

7

0.7

5.1

Rear exhaust pipe joint

Nut

M8

2

20

2.0

14

Muffler

Bolt

M10

1

53

5.3

38

Muffler

Bolt

M8

2

20

2.0

14

Muffler clamp

Bolt

M8

2

12

1.2

8.7

Crankcase (cylinder head)

Stud bolt

M12

8

See NOTE *1.

E

Crankcase (cylinder head)

Stud bolt

M10

4

See NOTE *2.

E

Crankcase (transfer gear case)

Stud bolt

M8

1

See NOTE *3.

E

Right crankcase

Bolt

M8

3

24

2.4

17

Right crankcase

Bolt

M6

3

10

1.0

7.2

Left crankcase

Bolt

M6

15

10

1.0

7.2

Crankshaft position sensor

Screw

M6

2

7

0.7

5.1

LT

Crankshaft position sensor lead 
holder

Screw

M6

7

7

0.7

5.1

LT

Stator coil assembly

Screw

M6

3

7

0.7

5.1

LT

Stator coil assembly

Bolt

M6

1

10

1.0

7.2

LT

Starter clutch

Bolt

M8

6

24

2.4

17

LT

Generator cover

Bolt

M6

11

10

1.0

7.2

Generator rotor

Bolt

M12

1

130

13.0

94

LT

Generator shaft

Bolt

M8

1

28

2.8

20

Generator shaft end cover

Bolt

M6

2

10

1.0

7.2

Crankshaft position sensor rotor

Bolt

M12

1

100

10.0

72

Clutch cover

Bolt

M6

11

10

1.0

7.2

Clutch boss

Nut

M20

1

85

8.5

61

Use a lock 
washer.

Clutch spring plate

Bolt

M6

6

8

0.8

5.8

Pull lever

Bolt

M6

1

12

1.2

8.7

Transfer gear oil drain bolt

—

M8

1

18

1.8

13

Middle drive gear

Nut

M22

1

100

10.0

72

Use a lock 
washer.

Item

Fastener

Thread 

size

Q’ty

Tightening torque

Remarks

Nm

m·kg

ft·lb

2 - 23

SPEC

TIGHTENING TORQUES

NOTE:

*1:Do not tighten the engine temperature sensor and oil temperature sensor beyond the specified

torques.

*2:When installing the crankcase stud bolts (cylinder head), make sure that their installed length is

141.5 mm (5.57 in).

*3:When installing the crankcase stud bolts (transfer gear case), make sure that their installed

length is 69.3 mm (2.73 in).

Cover

Bolt

M8

2

24

2.4

17

Cover

Bolt

M6

5

10

1.0

7.2

Oil tank left cover

Bolt

M6

16

10

1.0

7.2

Oil tank left cover

Bolt

M6

3

10

1.0

7.2

Oil strainer

Bolt

M6

1

10

1.0

7.2

Transfer gear case 

Bolt

M8

4

30

3.0

22

Transfer gear case cover

Nut

M8

1

30

3.0

22

Transfer gear oil checking bolt

Bolt

M6

1

8

0.8

5.8

Transfer gear oil pump cover

Bolt

M6

2

10

1.0

7.2

Transfer gear oil pump 

Bolt

M6

3

10

1.0

7.2

Drive sprocket case

Bolt

M10

3

50

5.0

36

Drive sprocket case

Bolt

M10

5

50

5.0

36

Drive sprocket 

Nut

M22

1

100

10.0

72

Use a lock 
washer.

Drive sprocket cover

Bolt

M6

1

7

0.7

5.1

Shift arm

Bolt

M6

1

12

1.2

8.7

Shift rod locknut

Nut

M8

2

12

1.2

8.7

Shift shaft spring stopper

Bolt

M8

1

22

2.2

16

LT

Shift drum assembly

Screw

M6

1

12

1.2

8.7

Shift drum assembly plate

Screw

M5

1

4

0.4

2.9

Stopper lever

Bolt

M6

1

10

1.0

7.2

LT

Neutral switch

Bolt

M6

2

4

0.4

2.9

Speed sensor

Bolt

M6

1

10

1.0

7.2

Intake air pressure sensor

Bolt

M5

2

5

0.5

3.6

Intake air temperature sensor

—

M8

1

15

1.5

11

Oil temperature sensor

—

M12

1

20

2.0

14

See NOTE *1.

Oil gallery bolt

Bolt

M8

3

20

2.0

14

Oil gallery bolt 

Bolt

M6

1

10

1.0

7.2

Oil gallery bolt 

Bolt

M5

3

9

0.9

6.5

Item

Fastener

Thread 

size

Q’ty

Tightening torque

Remarks

Nm

m·kg

ft·lb

2 - 24

SPEC

TIGHTENING TORQUES

CHASSIS TIGHTENING TORQUES

Item

Thread size

Tightening torque

Remarks

Nm

m·kg

ft·lb

Upper bracket and outer tube

M8

26

2.6

19

Lower bracket and outer tube

M8

23

2.3

17

Upper bracket and steering shaft

M28

115

11.5

85

Handlebar holder (lower) and handlebar holder 
(upper)

M8

28

2.8

20

Ring nut (steering shaft)

M30

4

0.4

2.9

See NOTE.

Brake hose joint and lower bracket

M6

7

0.7

5.1

Brake master cylinder reservoir cap

M4

2

0.2

1.4

Turn signal light bracket and lower bracket

M6

7

0.7

5.1

Turn signal light bracket pinch bolt

—

7

0.7

5.1

Headlight bracket and lower bracket

M8

23

2.3

17

Headlight bracket and brake hose joint

M6

7

0.7

5.1

Handlebar holder (lower)

M12

40

4.0

29

Front brake master cylinder

M6

10

1.0

7.2

Union bolt (brake hose)

M10

32

3.2

23

Engine mounting:

Spacer bolt

M18

18

1.8

13

Upper mounting bolt (upper engine bracket and 
engine)

M10

48

4.8

35

Upper engine bracket and frame

M10

48

4.8

35

Lower front mounting nut (frame and engine)

M12

105

10.5

75

Lower rear mounting nut (frame and engine)

M12

88

8.8

64

Rear engine bracket and frame

M10

53

5.3

38

Rear engine bracket and engine

M12

98

9.8

71

Front engine bracket and frame

M10

48

4.8

35

Front engine bracket and engine

M12

88

8.8

64

Transfer gear case and transfer gear case 
bracket

M10

63

6.3

45

Transfer gear case bracket and frame

M10

53

5.3

38

Muffler bracket and frame

M10

53

5.3

38

Muffler bracket and muffler

M8

20

2.0

14

Ignition coil

M6

7

0.7

5.1

Swingarm pivot shaft

M18

125

12.5

90

Relay arm and swingarm

M12

59

5.9

43

Relay arm and connecting rod

M12

59

5.9

43

Relay arm and rear shock absorber

M10

40

4.0

29

Rear shock absorber, connecting rod and frame

M12

59

5.9

43

Upper drive belt cover and swingarm

M6

7

0.7

5.1

Lower drive belt cover and swingarm

M6

7

0.7

5.1

2 - 25

SPEC

TIGHTENING TORQUES

Rear fender bracket and frame

M10

40

4.0

29

Rear fender bracket and rear fender

M8

23

2.3

17

Fuel tank and fuel filter

M6

7

0.7

5.1

Fuel tank bracket and frame

M6

10

1.0

7.2

Fuel tank and frame

M8

19

1.9

7.2

Sub fuel tank and frame

M6

10

1.0

7.2

Seat bracket and frame

M8

16

1.6

11

Side cover and side cover bracket

M6

4

0.4

2.9

Side cover bracket and frame 

M6

13

1.3

9.4

Side cover and seat bracket

M6

7

0.7

5.1

Starter relay and battery positive lead

M6

7

0.7

5.1

Starter relay and starter motor lead

M6

7

0.7

5.1

Battery box and frame

M6

7

0.7

5.1

Sidestand bracket and frame

M10

63

6.3

45

Sidestand and bolt

M12

122

12.2

88

Sidestand and nut

M12

88

8.8

64

Footrest bracket and frame

M10

48

4.8

35

Rear footrest and frame

M10

48

4.8

35

Front brake master cylinder holder

M6

10

1.0

7.2

Rear brake master cylinder and rear brake master 
cylinder bracket

M8

23

2.3

17

Rear brake master cylinder cover and frame

M8

23

2.3

17

Rear brake fluid reservoir 

M6

7

0.7

5.1

Union bolt (rear brake hose)

M10

30

3.0

22

Brake rod and rear brake master cylinder

M8

16

1.6

11

Front wheel axle

M18

72

7.2

52

Front wheel axle pinch bolt

M8

23

2.3

17

Rear wheel axle nut

M18

150

15.0

110

Front brake caliper

M10

40

4.0

29

Rear brake caliper

M10

27

2.7

19

Brake disc and wheel

M6

18

1.8

13

LT

Caliper bleed screw (front)

M8

6

0.6

4.3

Caliper bleed screw (rear)

M7

6

0.6

4.3

Rear wheel sprocket and rear wheel drive hub

M12

95

9.5

68

Rear brake caliper bracket and swingarm 

M10

30

3.0

22

Front fork guard and front fork

M8

16

1.6

11

Front fork guard and front fork

M6

13

1.3

9.4

Front fender and front fork leg

M8

16

1.6

11

Cap bolt and outer tube

—

23

2.3

17

Item

Thread size

Tightening torque

Remarks

Nm

m·kg

ft·lb