Manual de Taller HONDA CRF250L MANUAL TALLER 2012

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HOW TO USE THIS MANUAL

A Few Words About Safety

Service Information

The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting

service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the

vehicle or create an unsafe condition.

This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures

require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service

procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of

the vehicle.

If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend

that you do not use replacement parts of inferior quality.

For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while

servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety

practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge

of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.

Some of the most important general service safety precautions are given below. However, we cannot warn you of every

conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should

perform a given task.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and

using safety equipment. When performing any service task, be especially careful of the following:

• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills

required to perform the tasks safely and completely.

• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around

pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.

• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe

burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,

make sure that it is always securely supported. Use jack stands.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will

help eliminate several potential hazards:

• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine

• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.

• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.

Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when

working around gasoline or batteries.

• Use only a nonflammable solvent, not gasoline, to clean parts.

• Never drain or store gasoline in an open container.

• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

Improper service or repairs can create an unsafe

condition that can cause your customer or others to

be seriously hurt or killed.

Follow the procedures and precautions in this

manual and other service materials carefully.

Failure to properly follow instructions and

precautions can cause you to be seriously hurt or

killed.

Follow the procedures and precautions in this

manual carefully.

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HOW TO USE THIS MANUAL

How To Use This Manual

This manual describes the service procedures for the CRF250L.

Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may be

required to perform service described in the following sections.

Section 4 through 20 describe parts of the motorcycle, grouped according to location.

Follow the Maintenance Schedule recommendations to ensure that the motorcycle is in peak operating condition.

Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in

period.

Find the section you want on this page, then turn to the table of contents on the first page of the section.

Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent

pages give detailed procedure.

Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI

section troubleshooting first.

As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help

prevent damage to your vehicle, other property, or the environment.

SERVICE PUBLICATION OFFICE

Date of Issue: June, 2012

Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety

messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the

hazards associated with servicing this vehicle.

You must use your own good judgement.

You will find important safety information in a variety of forms including:

• Safety Labels – on the vehicle

• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE

BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda

Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT

INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT

WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF

MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.

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HOW TO USE THIS MANUAL

SYMBOLS

The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to

these symbols, it would be explained specifically in the text without the use of the symbols.

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or

equivalent).

Example:

• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.

• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan

Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or

equivalent).

Example:

• Molykote® G-n Paste manufactured by Dow Corning U.S.A.

• Honda Moly 60 (U.S.A. only)

• Rocol ASP manufactured by Rocol Limited, U.K.

• Rocol Paste manufactured by Sumico Lubricant, Japan

Use silicone grease.

Apply locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.

Use fork or suspension fluid.

CONTENTS

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GENERAL INFORMATION

FRAME/BODY PANELS/EXHAUST SYSTEM

MAINTENANCE

PGM-FI SYSTEM

IGNITION SYSTEM

ELECTRIC STARTER SYSTEM

FUEL SYSTEM

LUBRICATION SYSTEM

COOLING SYSTEM

CYLINDER HEAD/VALVES

CYLINDER/PISTON

CLUTCH/GEARSHIFT LINKAGE

ALTERNATOR/STARTER CLUTCH

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

ENGINE REMOVAL/INSTALLATION

FRONT WHEEL/SUSPENSION/STEERING

REAR WHEEL/SUSPENSION

BRAKE SYSTEM

BATTERY/CHARGING SYSTEM

LIGHTS/METERS/SWITCHES

WIRING DIAGRAM

INDEX

MEMO

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1. GENERAL INFORMATION

SERVICE RULES ··········································1-2

MODEL IDENTIFICATION ····························1-2

SPECIFICATIONS·········································1-4

TORQUE VALUES ········································1-9

LUBRICATION & SEAL POINTS ···············1-15

CABLE & HARNESS ROUTING·················1-17

EMISSION CONTROL SYSTEMS ··············1-27

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GENERAL INFORMATION

SERVICE RULES

1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design

specifications may cause damage to the motorcycle.

2. Use the special tools designed for this product to avoid damage and incorrect assembly.

3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English

fasteners.

4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.

5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in

incremental steps unless a particular sequence is specified.

6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.

7. After reassembly, check all parts for proper installation and operation.

8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-17).

9. Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.

ABBREVIATION

Throughout this manual, the following abbreviations are used to identify the respective parts or systems.

DESTINATION CODE

Throughout this manual, the following codes are used to identify individual types for each region.

MODEL IDENTIFICATION

Abbrev. term Full term

CKP sensor Crankshaft Position sensor

DLC Data Link Connector

DTC Diagnostic Trouble Code

ECM Engine Control Module

ECT sensor Engine Coolant Temperature sensor

EEPROM Electrically Erasable Programmable Read Only Memory

IACV Idle Air Control Valve

IAT sensor Intake Air Temperature sensor

MAP sensor Manifold Absolute Pressure sensor

MIL Malfunction Indicator Lamp

PAIR Pulse Secondary Air Injection

PGM-FI Programmed Fuel Injection

SCS connector Service Check Short connector

TP sensor Throttle Position sensor

VS sensor Vehicle Speed sensor

DESTINATION

CODE

REGION

EU.K.

FFrance

ED European direct sales

U Australia, New Zealand

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GENERAL INFORMATION

SERIAL NUMBERS/LABELS

The Vehicle Identification Number (V.I.N.) [1] is stamped on

the right side of the steering head.

The throttle body identification number [1] is stamped on the

lower left side of the throttle body.

The engine serial number [1] is stamped on the lower left side

of the crankcase.

The Registered Number Plate (except U type) /Compliance

plate (U type) [1] is stamped on the left front side of the

steering head.

The color label [1] is attached on the frame behind rear brake

master cylinder reservoir. When ordering color-coded parts,

always specify the designated color code.

[1]

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GENERAL INFORMATION

SPECIFICATIONS

GENERAL SPECIFICATIONS

ITEM SPECIFICATION

DIMENSIONS Overall length 2,195 mm (86.4 in)

Overall width 815 mm (32.1 in)

Overall height 1,195 mm (47.0 in)

Wheelbase 1,445 mm (56.9 in)

Seat height 875 mm (34.4 in)

Footpeg height 365 mm (14.4 in)

Ground clearance 255 mm (10.0 in)

Curb weight 143 kg (315 lbs)

Maximum weight capacity 159 kg (351 lbs)

FRAME Frame type Twin tube

Front suspension Telescopic fork

Front axle travel 222 mm (8.7 in)

Rear suspension Swingarm

Rear axle travel 240 mm (9.4 in)

Tire size Front 3.00-21 51P

Rear 120/80-18M/C 62P

Tire brand Front GP-21F Z (IRC)

Rear GP-22R (IRC)

Front brake Hydraulic single disc

Rear brake Hydraulic single disc

Caster angle 27° 35’

Trail length 113 mm (4.4 in)

Fuel tank capacity 7.7 liter (2.03 US gal, 1.69 Imp gal)

ENGINE Cylinder arrangement Single cylinder inclined 20° from vertical

Bore and stroke 76.0 x 55.0 mm (2.99 x 2.17 in)

Displacement 249.6 cm

(15.23 cu-in)

Compression ratio 10.7:1

Valve train Chain driven DOHC with rocker arm

Intake valve opens at 1.0 mm (0.04 in) lift 20° BTDC

closes at 1.0 mm (0.04 in) lift 35° ABDC

Exhaust valve opens at 1.0 mm (0.04 in) lift 40° BBDC

closes at 1.0 mm (0.04 in) lift 0° TDC

Lubrication system Forced pressure and wet sump

Oil pump type Trochoid

Cooling system Liquid cooled

Air filtration Viscous paper filter

Engine dry weight 34.5 kg (76.1 lbs)

FUEL DELIVERY

SYSTEM

Type PGM-FI

Throttle bore 36 mm (1.4 in)

DRIVE TRAIN Clutch system Multi-plate, wet

Clutch operation system Cable operating

Transmission Constant mesh, 6 speeds

Primary reduction 2.807 (73/26)

Final reduction 2.857 (40/14)

Gear ratio 1st 3.333 (40/12)

2nd 2.117 (36/17)

3rd 1.571 (33/21)

4th 1.304 (30/23)

5th 1.115 (29/26)

6th 0.962 (26/27)

Gearshift pattern Left foot operated return system

1 - N - 2 - 3 - 4 - 5 - 6

ELECTRICAL Ignition system Computer-controlled digital transistorized

with electric advance

Starting system Electric starter motor

Charging system Triple phase output alternator

Regulator/rectifier SCR shorted, triple phase full-wave

rectification

Lighting system Battery

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GENERAL INFORMATION

PGM-FI SYSTEM SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

ELECTRIC STARTER SPECIFICATION

Unit: mm (in)

FUEL SYSTEM SPECIFICATIONS

LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm (in)

ITEM SPECIFICATIONS

Fuel injector resistance (20°C/68°F) 11 – 13 

ITEM SPECIFICATION

Spark plug SIMR8A9 (NGK)

Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in)

Ignition coil peak voltage 100 V minimum

CKP sensor peak voltage 0.7 V minimum

Ignition timing ("F" mark) 10° BTDC at idle

ITEM STANDARD SERVICE LIMIT

Starter motor brush length 11.8 – 12.3 (0.46 – 0.48) 6.5 (0.26)

ITEM SPECIFICATIONS

Throttle body identification number GQ32A

Engine idle speed 1,450 ± 100 min

-1

(rpm)

Throttle grip freeplay 2 – 6 mm (0.08 – 0.24 in)

Fuel pressure at idle 343 kPa (3.5 kgf/cm

, 50 psi)

Fuel pump flow (at 12 V) 83 cm

(2.81 US oz, 2.92 Imp oz) minimum/10 seconds

PAIR control solenoid valve resistance (20°C/68°F) 20 – 24 

ITEM STANDARD SERVICE LIMIT

Engine oil capacity At draining 1.4 liters (1.5 US qt, 1.2 Imp qt) –

At oil filter change 1.5 liters (1.6 US qt, 1.3 Imp qt) –

At disassembly 1.8 liters (1.9 US qt, 1.6 Imp qt) –

Recommended engine oil Honda "4-stroke motorcycle oil" or an

equivalent

API classification: SG or higher (except

oils labeled as energy conserving on the

circular API service label)

Viscosity: SAE 10W-30

JASO T 903 standard: MA

–

Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)

Body clearance 0.15 – 0.22 (0.006 – 0.009) 0.35 (0.014)

Side clearance 0.02 – 0.09 (0.001 – 0.004) 0.10 (0.004)

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GENERAL INFORMATION

COOLING SYSTEM SPECIFICATIONS

CYLINDER HEAD/VALVES 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

, 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 STANDARD SERVICE LIMIT

Cylinder compression at 490 min

-1

(rpm) 1,294 kPa (13.2 kgf/cm

, 188 psi) –

Valve clearance IN 0.16 ± 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 Inner 34.58 (1.361) 32.85 (1.293)

Outer 40.37 (1.589) 38.35 (1.510)

Rocker arm,

rocker arm

shaft

Arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)

Shaft O.D. IN/EX 9.972 – 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 STANDARD SERVICE 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 CLUTCH SPECIFICATIONS

Unit: mm (in)

CRANKCASE/CRANKSHAFT/TRANSMISSION/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 STANDARD SERVICE 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 STANDARD SERVICE 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, M6 23.000 – 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 INFORMATION

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)

REAR WHEEL/SUSPENSION SPECIFICATIONS

Unit: mm (in)

BRAKE SYSTEM SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Minimum tire thread depth – 3.0 (0.12)

Cold tire pressure Driver only 150 kPa (1.50 kgf/cm

, 22 psi) –

Driver and passenger 150 kPa (1.50 kgf/cm

, 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

(22.3 ± 0.08 US oz, 23.2 ± 0.09 Imp oz)

–

Left 683 ± 2.5 cm

(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 STANDARD SERVICE LIMIT

Minimum tire thread depth – 3.0 (0.12)

Cold tire pressure Driver only 150 kPa (1.50 kgf/cm

, 22 psi) –

Driver and passenger 150 kPa (1.50 kgf/cm

, 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) –

ITEM STANDARD SERVICE 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) –

1-9

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GENERAL INFORMATION

BATTERY/CHARGING SYSTEM 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 

ITEM SPECIFICATION

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 TYPE

TORQUE

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)

1-10

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GENERAL INFORMATION

ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for important fasteners.

• Others should be tightened to standard torque values listed above.

FRAME/BODY PANELS/EXHAUST SYSTEM

MAINTENANCE

PGM-FI SYSTEM

ITEM Q'TY

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 Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Throttle cable A adjuster lock nut (throttle

body side) 1 6 3.0 (0.3, 2.2)

Air cleaner cover screw 4 5 1.2 (0.1, 0.9)

Spark plug 1 10 16 (1.6, 12)

Crankshaft hole cap 1 30 8.0 (0.8, 5.9) Apply engine oil to the

threads.

Timing hole cap 1 14 6.0 (0.6, 4.4) Apply engine oil to the

threads.

Engine oil drain bolt 1 12 24 (2.4, 18)

Drive chain adjuster lock nut 2 8 27 (2.8, 20) UBS nut

Rear axle nut 1 16 88 (9.0, 65) U-nut

Drive sprocket fixing plate bolt 2 6 10 (1.0, 7)

Driven sprocket nut 6 10 50 (5.1, 37) U-nut

Rear master cylinder reservoir mounting

bolt

1 6 10 (1.0, 7)

Master cylinder reservoir cover screw 4 4 1.5 (0.2, 1.1)

Rear master cylinder push rod lock nut 1 8 17.2 (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)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Sensor unit torx screw 3 5 3.4 (0.3, 2.5)

ECT sensor 1 12 25 (2.5, 18)

2 sensor 1 12 25 (2.5, 18)

Bank angle sensor mounting nut 2 6 9.0 (0.9, 6.6)

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