3
Torque Specifications
*w/Red Loctite #271
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance (max) 0.12 mm
Cylinder Bore 72.705-72.715 mm
Piston Diameter 18 mm from Skirt End
(max)
72.625 mm
Bore x Stroke 72.7 x 65.2 mm
Cylinder Trueness (max) 0.05 mm
Piston Ring to Groove Clearance (max)
(1st/2nd)
0.09 mm
Piston Ring End Gap - Installed (top)
(middle)
(oil)
0.15-0.30 mm
0.30-0.45 mm
0.20-0.70 mm
Piston Pin Bore (max) 17.06 mm
Piston Pin Outside Diameter (min) 16.96 mm
CRANKSHAFT
Connecting Rod (small end inside
diameter) (max)
17.06 mm
Connecting Rod (big end side-to-side) 0.05-0.40 mm
Connecting Rod (small end deflection)
(max)
1 mm
Crankshaft (web-to-web) 55.15-55.20 mm
Crankshaft Runout (max) 0.1 mm
Oil Pressure at 60°C (140°F) (above)
@ 3000 RPM (below)
0.3 kg/cm² (4.3 psi)
0.7 kg/cm² (10 psi)
TRANSMISSION
Clutch Release Screw 1/8 turn back
Drive Plate (fiber) Thickness (min) 2.4 mm
Drive Plate (fiber) Tab (min) 11 mm
Driven Plate (warpage) (max) 0.1 mm
Clutch Spring Length (min) 27.5 mm
Clutch Wheel Inside Diameter (max) Scuffing of contact surface
Clutch Shoe Lining Thickness 0.5 mm
Clutch Engagement RPM 2000 ± 200
Clutch Lock-Up RPM 3400 ± 300
VALVES AND GUIDES
Valve/Tappet Clearance (intake/exhaust)
(cold engine)
0.1 mm
Valve Guide/Stem Clearance (intake)
(max) (exhaust)
0.06 mm
0.08 mm
Valve Spring Free Length (min) (inner)
(outer)
29.4 mm
39.0 mm
Valve Spring Tension @ 18.0 mm (intake) 10.2-11.8 kg (22.5-26.0 lb)
Valve Spring Tension (exhaust)
@ 21.5 mm
19.05-22.0 kg (42.0-48.5 lb)
STEERING COMPONENTS
Part Part Bolted To
Torque
ft-lb N-m
Handlebar Clamp Cap Screw Steering Head 18 24
Steering Post Support Block Frame 17 23
Steering Post Nut Steering Post 50 68
Upper And Lower Ball Joint Nut Steering Knuckle 22 30
Tie Rod End Nut Steering Knuckle 15 20
Tie Rod Lock Nut Tie Rod 15 20
ELECTRICAL COMPONENTS
Starter Motor Lead Cable Nut Starter 36
in.-lb
4
Starter Motor Mounting Bolt Crankcase 9 12
EXHAUST COMPONENTS
Exhaust Pipe Engine 25 34
Muffler Mounting Bolt Frame 25 34
BRAKE COMPONENTS
Part Part Bolted To
Torque
ft-lb N-m
Brake Hose Union Bolt Master Cylinder/
Caliper
25 34
Brake Bleed Screw Caliper 56
in.-lb
6
Brake Caliper Mounting Cap Screw Steering Knuckle/
Swing Arm
25 34
Master Cylinder (Front) Handlebar 13 18
Brake Pad Mounting Pin (Front/Rear) Brake Caliper 13 18
Brake Caliper Slide Pin (Front/Rear) Brake Caliper 25 34
Front Brake Line Nut Brake Line/Junction
Block
25 34
Brake Caliper (Rear) Swing Arm Housing 25 34
SUSPENSION COMPONENTS (Front)
A-Arm Pivot Nut Frame 32 44
Front Shock Absorber Mounting Nut*
(Upper/Lower)
Frame 29 39
SUSPENSION COMPONENTS (Rear)
Left Pivot Bolt Swing Arm 36
in.-lb
4
Right Pivot Bolt Swing Arm 82 112
Left Pivot Lock Nut Left Pivot Bolt 82 112
Rear Shock Absorber Mounting Nut
(Upper/Lower)
Frame/Swing Arm 29 39
Axle Housing Cap Screw Final Drive Gear
Case
40 54
DRIVE TRAIN COMPONENTS
Engine Mounting Through-Bolt Frame 29 39
Engine Mounting Bracket Cap Screw Frame 16 22
Rear Axle Housing Swing Arm 40 54
Gear Case Swing Arm 50 68
Pinion Nut Shaft 72 98
Gear Case Cover (8 mm)
(10 mm)
Gear Case 19
36
26
49
Hub Nut (Front) Front/Spindle 50 68
Wheel Lug Nut Hub 40 54
Hub Nut (Rear) Axle 72 98
Rear Axle Nut* Axle 72 98
ENGINE/TRANSMISSION
Cylinder Head Cylinder 7 10
Cylinder Nut Crankcase 7 10
Camshaft Holder Cylinder Head 18 24
Bevel Drive Gear Driveshaft 72 98
Magneto Rotor/Flywheel Crankshaft 47 64
Bevel Driven Gear Driven Shaft 72 98
Crankcase Cap Screw Crankcase 8 11
Engine Oil Screen/Filter Cap Crankcase 11 15
Shift Cam Stopper Plug* Left Case 20 27
Camshaft Chain Tensioner Adjuster Cam Chain
Tensioner
912
Cam Chain Tensioner Cover Bolt Tensioner 24
in.-lb
3
Starter Ratchet Crankshaft 68 92
Camshaft Chain Tensioner Mount Cylinder Head 9 12
Camshaft Chain Tension Spring Holder
Plug
Cam Chain
Tensioner
36
in.-lb
4
Centrifugal Clutch Housing Driveshaft 40 54
Timing Plug Right Case 16 22
Driven Pulley Retaining Nut Driven Shaft
(Transmission)
43 59
Drive Plate Nut* Fixed Driven Face 43 59
Drive Pulley Nut Crankshaft 72 98
Engine Oil Drain Plug Crankcase 21 29
Transmission Drain Plug Transmission 21 29
Transmission Case Cover Transmission 20 27
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