Manual de Taller HONDA ELITE SC125 MANUAL TALLER 2004

TYPE CODE

• Throughout this manual, the following abbreviations are used to identify individual model.

CODE AREA TYPE

CH China

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 genuine Honda 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.

HOW TO USE THIS MANUAL

This service manual describes the service procedures for the SC125 - 5.

Follow the Maintenance Schedule (Section 3) recommendations to

ensure that the vehicle 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.

Sections 1 and 3 apply to the whole scooter. Section 2 illustrates

procedures for removal/installation of components that may be required

to perform service described in the following sections.

Section 4 through 19 describe parts of the scooter, grouped according to

location.

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.

If you don't know the source of the trouble, go to section 21

Troubleshooting.

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:

YouWILLbeKILLEDorSERIOUSLY

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.

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.

ALL INFORMATION, ILLUSTRATIONS, DIREC-

TIONS AND SPECIFICATIONS INCLUDED IN

THIS PUBLICATION ARE BASED ON THE LAT-

EST 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 OBLI-

GATION WHATSOEVER. NO PART OF THIS

PUBLICATION MAY BE REPRODUCED WITH-

OUT WRITTEN PERMISSION. THIS MANUAL IS

WRITTEN FOR PERSONS WHO HAVE

ACQUIRED BASIC KNOWLEDGE OF MAINTE-

NANCE ON Honda MOTORCYCLES, MOTOR

SCOOTERS OR ATVS.

Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE

CONTENTS

GENERAL INFORMATION

FRAME/BODY PANELS/EXHAUST

SYSTEM

MAINTENANCE

LUBRICATION SYSTEM

ENGINE AND DRIVE TRAIN

FUEL SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

KICKSTARTER/DRIVE PULLEY/

DRIVEN PULLEY/CLUTCH

FINAL REDUCTION

ALTERNATOR/STARTER CLUTCH

CRANKCASE/CRANKSHAFT

FRONT WHEEL/

SUSPENSION/STEERING

REAR WHEEL/BRAKE/SUSPENSION

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

ELECTRIC STARTER

LIGHTS/METER/SWITCHES

WIRING DIAGRAMS

TROUBLESHOOTING

CHASSIS

ELECTRICAL

INDEX

Date of Issue: September, 2004

©Honda Motor Co., Ltd.

HYDRAULIC BRAKE

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 recommended 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 a locking agent. Use a middle 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.

1-1

1. GENERAL INFORMATION

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

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

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

LUBRICATION SYSTEM SPECIFICATIONS · 1-5

FUEL SYSTEM SPECIFICATIONS················· 1-5

CYLINDER HEAD/VALVES

SPECIFICATIONS··········································· 1-5

CYLINDER/PISTON SPECIFICATIONS········· 1-6

KICKSTARTER/DRIVE PULLEY/DRIVEN

PULLEY/CLUTCH SPECIFICATIONS ············ 1-6

FINAL REDUCTION SPECIFICATIONS ········· 1-6

CRANKCASE/CRANKSHAFT

SPECIFICATIONS··········································· 1-6

FRONT WHEEL/SUSPENSION/STEERING

SPECIFICATIONS··········································· 1-7

REAR WHEEL/BRAKE/SUSPENSION

SPECIFICATIONS············································1-7

HYDRAULIC BRAKE SPECIFICATIONS·········1-7

BATTERY/CHARGING SYSTEM

SPECIFICATIONS············································1-8

IGNITION SYSTEM SPECIFICATIONS ··········1-8

ELECTRIC STARTER SPECIFICATIONS ········1-8

LIGHTS/METER/SWITCHES

SPECIFICATIONS············································1-8

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

ENGINE & FRAME TORQUE VALUES ··········1-9

LUBRICATION & SEAL POINTS ··················1-14

CABLE & HARNESS ROUTING ···················1-16

EMISSION CONTROL SYSTEMS ················1-26

GENERAL INFORMATION

1-2

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 scooter.

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

3. Use only metric tools when servicing the scooter. 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 1-16).

MODEL IDENTIFICATION

This manual covers 4 type of SC125 models.

• Type I :Rear hand brake

• Type II :Rear foot brake

• Type III :Rear hand brake/Ignition switch key shutter

• Type IV :Rear foot brake/Ignition switch key shutter

GENERAL INFORMATION

1-3

The frame serial number is stamped on the right side of the frame.

The engine serial number is stamped on the lower left side of the

crankcase.

The carburetor identification number is stamped on the left side of the

carburetor body.

The color label is attached as shown. When ordering color-coded parts,

always specify the designated color code.

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

CARBURETOR IDENTIFICATION NUMBER

COLOR LABEL

GENERAL INFORMATION

1-4

GENERAL SPECIFICATIONS

ITEM SPECIFICATION

DIMENSIONS Overall length 1,785 mm (70.3 in)

Overall width 694 mm (27.3 in)

Overall height 1,139 mm (44.8 in)

Wheelbase 1,211 mm (47.7 in)

Seat height 752 mm (29.6 in)

Ground clearance 121 mm (4.8 in)

Dry weight TYPE I, III 104 kg (229 lbs)

TYPE II, IV 106 kg (234 lbs)

Curb weight 109 kg (240 lbs)

Maximum weight capacity 176 kg (388 lbs)

FRAME Frame type Under bone

Front suspension Bottom link

Front axle travel 64 mm (2.5 in)

Rear suspension Unit swing

Rear axle travel 64 mm (2.5 in)

Front tire size 90/100 – 10 53J

Rear tire size 90/100 – 10 53J

Tire

brand

CHENG SHIN Front/Rear: C6027

DURO Front/Rear: HFC-263A

Front brake Hydraulic single disc

Rear brake Mechanical leading trailing

Caster angle 27° 00’

Trail length 80 mm (3.1 in)

Fuel tank capacity 6.0 liter (1.59 US gal, 1.32 lmp gal)

ENGINE Type Gasoline air-cooled 4-stroke

Cylinder arrangement 10° Include from holizontal

Bore and stroke 52.4 x 57.8 mm (2.05 x 2.28 in)

Displacement 124.6 cm

(7.60 cu-in)

Compression ratio 9.2: 1

Valve train Chain driven, OHC

Intake valve opens 0° TDC (at 1 mm lift)

Intake valve closes 25° ABDC (at 1 mm lift)

Exhaust valve opens 33° BBDC (at 1 mm lift)

Exhaust valve closes 0° TDC (at 1 mm lift)

Lubrication system Forced pressure and wet sump

Oil pump type Trochoid

Cooling system Forced air cooled

Air filtration Paper filter

Engine dry weight 25.5 kg (56.2 lbs)

CARBURETOR Carburetor type CV (Constant Velocity)

Throttle bore 24 mm (0.9 in)

DRIVE TRAIN Clutch system Dry, automatic centrifugal clutch

Drive belt ratio 2.640 – 0.860

Final reduction ratio 8.615

ELECTRICAL Ignition system DC-CDI

Starting system Electric starter motor/kickstarter

Charging system Single phase alternator

Regulator/rectifier SCR shorted/single phase, half-wave rectification

Lighting system Alternator

GENERAL INFORMATION

1-5

LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm (in)

FUEL SYSTEM SPECIFICATIONS

CYLINDER HEAD/VALVES SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Engine oil capacity After draining 0.8 liter (0.8 US qt, 0.7 lmp qt) –

After disassembly 0.9 liter (1.0 US qt, 0.8 lmp qt) –

Recommended engine oil Honda 4-stroke oil

or equivalent motor oil

API service classification: SE, SF or SG

Viscosity: SAE 10W-30

–

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

Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.25 (0.010)

Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)

ITEM SPECIFICATIONS

Carburetor identification number VE49E

Main jet #102

Slow jet #35

SE thermal valve resistance 5 Ω (20°C/68°F)

Float level 18.5 mm (0.73 in)

Pilot screw initial opening See page 5-21

Idle speed 1,700 ± 100 min

-1

(rpm)

PAIR control valve specified vacuum 60 kPa (450 mmHg)

SE thermal valve resistor resistance 7.6 – 9.4 Ω (20°C/68°F)

Throttle grip free play 2 – 6 mm (0.1 – 0.2 in)

ITEM STANDARD SERVICE LIMIT

Cylinder compression 1,275 kPa (13.0 kgf/cm

, 185 psi)

at 570 min

-1

(rpm)

–

Cylinder head warpage – 0.05 (0.002)

Valve clearance IN/EX 0.14 (0.006) –

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

Rocker arm 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) 0.08 (0.003)

Camshaft Cam lobe height IN 25.885 – 26.045 (1.0191 – 1.0254) 25.815 (1.0163)

EX 25.730 – 25.890 (1.0130 – 1.0193) 25.660 (1.0102)

Valve, valve

guide

Valve stem O.D. IN 4.975– 4.990 (0.1959 – 0.1965) 4.90 (0.193)

EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)

Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)

Stem-to-guide

clearance

IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)

EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)

Valve seat width IN/EX 1.0 (0.04) 1.6 (0.06)

Valve spring free length Inner 32.41 (1.276) 32.01 (1.260)

Outer 35.25 (1.388) 34.85 (1.372)

GENERAL INFORMATION

1-6

CYLINDER/PISTON SPECIFICATIONS

Unit: mm (in)

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

SPECIFICATIONS

Unit: mm (in)

FINAL REDUCTION SPECIFICATIONS

CRANKCASE/CRANKSHAFT SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder I.D. 52.40 – 52.41 (2.0630 – 2.0634) 52.50 (2.067)

Out-of-round – 0.05 (0.002)

Taper – 0.05 (0.002)

Warpage – 0.05 (0.002)

Piston,

piston

ring,

piston pin

Piston O.D. 52.370 – 52.390 (2.0618 – 2.0626) 52.30 (2.059)

Piston O.D. measurement point 10 (0.39) from bottom of skirt –

Piston pin bore I.D. 15.002 – 15.008 (0.5906 – 0.5909) 15.04 (0.592)

Piston pin O.D. 14.994 – 15.000 (0.5903 – 0.5906) 14.96 (0.589)

Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)

Piston ring-to-ring groove

clearance

Top 0.030 – 0.065 (0.0012 – 0.0026) 0.09 (0.004)

Second 0.015 – 0.050 (0.0006 – 0.0020) 0.09 (0.004)

Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.010) 0.50 (0.020)

Second 0.25 – 0.40 (0.010 – 0.016) 0.60 (0.024)

Oil (side

rail)

0.20 – 0.80 (0.008 – 0.031) –

Cylinder-to-piston clearance 0.010 – 0.040 (0.0004 – 0.0016) 0.10 (0.004)

Connecting rod small end I.D. 15.016 – 15.034 (0.5912 – 0.5919) 15.06 (0.593)

Connecting rod-to-piston pin clearance 0.016 – 0.040 (0.0006 – 0.0016) 0.06 (0.002)

ITEM STANDARD SERVICE LIMIT

Drive belt width 20.0 (0.79) 19.0 (0.75)

Movable

drive face

Bushing I.D. 23.989 – 24.042 (0.9444 – 0.9465) 24.07 (0.948)

Boss O.D. 23.960 – 23.974 (0.9433 – 0.9439) 23.93 (0.942)

Weight roller O.D. 17.92 – 18.08 (0.706 – 0.712) 17.5 (0.69)

Clutch Lining thickness – 2.0 (0.08)

Clutch outer I.D. 125.0 – 125.2 (4.92 – 4.93) 125.5 (4.94)

Driven pulley Face spring free length 154.6 (6.09) 135 (5.3)

Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)

Movable driven face I.D. 34.000 – 34.025 (1.3386 – 1.3396) 34.06 (1.341)

ITEM SPECIFICATIONS

Final reduction oil

capacity

After draining 0.09 liter (0.10 US qt, 0.08 lmp qt)

After disassembly 0.11 liter (0.12 US qt, 0.10 lmp qt)

Recommended final reduction oil Hypoid gear oil SAE #90 or

Honda 4-stroke oil or equivalent motor oil

API service classification: SE, SF or SG

Viscosity: SAE 10W-30

ITEM STANDARD SERVICE LIMIT

Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)

Connecting rod radial clearance 0 – 0.008 (0 – 0.0003) 0.05 (0.002)

Runout – 0.10 (0.004)

GENERAL INFORMATION

1-7

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)

REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS

Unit: mm (in)

HYDRAULIC BRAKE SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Minimum tire tread depth – To the indicator

Cold tire

pressure

Driver only 175 kPa (1.75 kgf/cm

, 25 psi) –

Driver and passenger 175 kPa (1.75 kgf/cm

, 25 psi) –

Axle runout – 0.2 (0.01)

Wheel rim

runout

Radial – 2.0 (0.08)

Axial – 2.0 (0.08)

ITEM STANDARD SERVICE LIMIT

Minimum tire tread depth – To the indicator

Cold tire

pressure

Drive only 200 kPa (2.00 kgf/cm

, 29 psi) –

Drive and passenger 250 kPa (2.50 kgf/cm

, 36 psi) –

Wheel rim

runout

Radial – 2.0 (0.08)

Axial – 2.0 (0.08)

Rear brake Brake lever free play (Type I, III) 10 – 20 (0.4 – 0.8) –

Brake pedal free play (Type II, IV) 20 – 30 (0.8 – 1.2) –

Brake drum I.D. 110.0 (4.33) 111.0 (4.4)

ITEM STANDARD SERVICE LIMIT

Specified brake fluid DOT 3 or DOT 4 –

Brake disc thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)

Brake disc warpage – 0.2 (0.01)

Master cylinder I.D. 14.000 – 14.043 (0.5512 – 0.5529) 14.055 (0.5533)

Master piston O.D. 13.957 – 13.984 (0.5495 – 0.5506) 13.945 (0.5490)

Caliper cylinder I.D. 25.400 – 25.450 (1.0000 – 1.0020) 25.460 (1.0024)

Caliper piston O.D. 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)

GENERAL INFORMATION

1-8

BATTERY/CHARGING SYSTEM SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

ELECTRIC STARTER SPECIFICATIONS

Unit: mm (in)

LIGHTS/METER/SWITCHES SPECIFICATIONS

ITEM SPECIFICATIONS

Battery Capacity 12 V – 6 Ah

Current leakage 0.5 mA max.

Voltage Fully charged Above 12.8 V

Needs charging Below 12.3 V

Charging

current

Normal 0.6 A/5 – 10 h

Quick 3.0 A/1.0 h

Alternator Capacity 0.125 kW/5,000 min

-1

(rpm)

Charging coil resistance 0.2 – 1.0 Ω (20°C/68°F)

Lighting coil resistance 0.1 – 0.8 Ω (20°C/68°F)

Regulator/rectifier regulated voltage (Lighting output) 12.6 – 13.6 V/5,000 min

-1

(rpm)

ITEM SPECIFICATIONS

Spark plug CR7HSA (NGK)

Spark plug gap 0.6 – 0.7 mm (0.02 – 0.03 in)

Ignition coil peak voltage 100 V minimum

Ignition pulse generator peak voltage 0.7 V minimum

Ignition timing ("F" mark) 13° BTDC at idle speed

ITEM STANDARD SERVICE LIMIT

Starter motor brush length 11.9 (0.47) 9.4 (0.37)

ITEM SPECIFICATIONS

Bulbs Headlight Hi 12V – 35 W

Lo 12V – 35 W

Position light 12V – 5 W

Brake/tail light 12V – 21/5 W

Turn signal light 12V – 21 W X 4

Meter light 12V – 1.7 W X 2

Turn signal indicator 12V – 3.4 W X 2

High beam indicator 12V – 1.7 W

Fuse Main fuse 20 A

Sub fuse 15 A

Lighting resistor resistance 5.3 – 6.5 Ω (20°C/68°F)

GENERAL INFORMATION

1-9

STANDARD TORQUE VALUES

ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for specified fasteners.

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

1. Apply engine oil to the threads and seating surface.

2. Apply sealant to the threads.

3. Apply a locking agent to the threads.

4. ALOC bolt: replace with a new one.

5. U-nut.

6. Left hand threads.

ENGINE

MAINTENANCE

LUBRICATION SYSTEM

FUEL SYSTEM

TORQUE TORQUE

FASTENER TYPE N·m (kgf·m, lbf·ft) FASTENER TYPE N·m (kgf·m, lbf·ft)

5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)

6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)

8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head; small

head)

10 (1.0, 7)

10 mm bolt and nut 34 (3.5, 25) 6 mm flange bolt (8 mm head; large

flange)

12 (1.2, 9)

12 mm bolt and nut 54 (5.5, 40) 6 mm flange bolt (10 mm head) and

nut

12 (1.2, 9)

8 mm flange bolt and nut 26 (2.7, 20)

10 mm flange bolt and nut 39 (4.0, 29)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Spark plug 1 10 12 (1.2, 9)

Air cleaner housing cover screw 7 5 1.1 (0.1, 0.7)

Valve adjusting lock nut 2 5 9 (0.9, 6.5) NOTE 1

Engine oil strainer screen cap 1 30 15 (1.5, 11)

Engine oil drain bolt 1 12 24 (2.4, 17)

Final reduction oil check bolt 1 8 12 (1.2, 9)

Final reduction oil drain bolt 1 8 12 (1.2, 9)

Secondary air cleaner housing cover screw 1 5 1.1 (0.1, 0.7)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Oil pump plate screw 1 3 2 (0.2, 1.4)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Carburetor drain screw 1 – 1.5 (0.2, 1.1)

SE thermal valve set plate screw 1 4 2.1 (0.2, 1.5)

SE thermal valve body screw 2 5 3.5 (0.4, 2.9)

Throttle cable holder screw 2 5 3.5 (0.4, 2.9)

Air cut-off valve cover screw 2 4 2.1 (0.2, 1.5)

Vacuum chamber cover screw 2 4 2.1 (0.2, 1.5)

Float chamber screw 4 4 2.1 (0.2, 1.5)

Slow jet 1 – 1.8 (0.2, 1.3)

Needle jet holder 1 – 2.5 (0.3, 1.8)

Main jet 1 – 2.1 (0.2, 1.5)

Carburetor insulator band screw 1 4 2 (0.2, 1.4)

PAIR pipe mounting bolt 3 6 10 (1.0, 7)

Fuel auto valve lock nut 1 16 18 (1.8, 13)

GENERAL INFORMATION

1-10

CYLINDER HEAD/VALVES

CYLINDER/PISTON

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

FINAL REDUCTION

ALTERNATOR/STARTER CLUTCH

CRANKCASE/CRANKSHAFT

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Cam chain tensioner lifter screw 1 6 4 (0.4, 2.9)

Cam chain tensioner lifter bolt 2 6 12 (1.2, 9)

Camshaft holder nut 4 8 20 (2.0, 14) NOTE 1

Intake shroud mounting screw 2 5 0.9 (0.1, 0.7)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Cylinder stud bolt A 2 8 9 (0.9, 6.5)

Cylinder stud bolt B 2 8 9 (0.9, 6.5)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Kickstarter pinch bolt 1 6 14 (14, 10)

Left crankcase cover bolt 9 6 12 (1.2, 9)

Left crankcase cover plate screw 4 4 3 (0.3, 2.2)

Drive pulley face nut 1 12 59 (6.0, 43) NOTE 1

Clutch/driven pulley nut 1 28 54 (5.5, 40)

Clutch outer nut 1 12 54 (5.5, 40)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Transmission cover bolt 1 6 12 (1.2, 9)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Cooling fan cover screw 2 5 0.9 (0.1, 0.7)

Flywheel nut 1 12 54 (5.5, 40)

Starter clutch lock nut 1 22 93 (9.5, 69) NOTE 1, 6

Starter clutch socket bolt 3 6 12 (1.2, 9) NOTE 3

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Cam chain tensioner slider pivot special bolt 1 6 10 (1.0, 7)

GENERAL INFORMATION

1-11

Air cleaner connecting hose band screw:

PAIR pipe band screw:

9.0 ± 1.0 mm

(0.35 ± 0.04 in)

4.0 ± 1.0 mm

(0.16 ± 0.04 in)

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