TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart:
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1 TIGHTENING TORQUE ENGINE ITEM N m kgfm lbft Cylinder head cover bolt Spark plug Cylinder head bolt (M10) (M6) Cylinder bolt Camshaft journal holder bolt Balancer driven gear nut Primary drive gear nut Generator rotor nut Clutch sleeve hub nut Gearshift lever bolt Gearshift arm stopper Starter clutch bolt Gearshift cam driven gear bolt Cam chain tension adjuster mounting bolt Cam chain tensioner mounting bolt Cam chain tension spring holder bolt Engine oil drain plug (on the crankcase) Engine oil drain bolt (on the oil tank) Crankcase bolt Gear position switch bolt Oil hose mounting bolt Starter motor mounting bolt TDC plug Generator cover cap Engine mounting bolt Engine mounting bracket bolt Exhaust pipe nut Muffler connection bolt Muffler mounting bolt Engine sprocket bolt Intake pipe mounting bolt Fl SYSTEM AND INTAKE AIR SYSTEM ITEM N m kgfm lbft CKP sensor mounting bolt IAT sensor mounting screw Fuel delivery pipe mounting screw Fuel pump mounting bolt TP sensor mounting screw
2 COOLING SYSTEM ITEM Wm kgfm lbft Water pump cover screw Water pump cover bolt Engine coolant drain plug ECT sensor Thermostat cover bolt CHASSIS ITEM N m kgfm lbft Handlebar clamp bolt Handlebar holder nut Steering shaft holder bolt Steering shaft lower nut Steering arm plate bolt Steering knuckle end nut (Upper & Lower) Tie rod end nut Tie rod locknut Front shock absorber mounting nut (Upper & Lower) Wishbone arm pivot nut Wheel hub nut (Front) (Rear) Wheel set nut (Front & Rear) Brake hose union bolt Brake disc bolt (Front & Rear) Brake air bleeder valve Brake caliper mounting bolt (Front & Rear) Brake master cylinder mounting bolt (Front & Rear) Front brake lever pivot bolt Front brake lever pivot bolt locknut Front brake caliper holder pin Front brake caliper holder nut Front brake pipe nut Front brake pad mounting pin Rear brake master cylinder rod locknut Rear brake pedal pivot bolt Rear brake pad mounting pin Rear brake caliper holder pin Rear brake caliper holder slide pin Parking brake housing bolt Parking brake adjuster locknut Footrest mounting bolt Seat rail bolt (Upper & Lower) Rear sprocket mounting bolt Rear axle nut Rear axle locknut Rear axle housing set nut Swingarm pivot nut Rear shock absorber mounting nut (Upper & Lower) Cushion lever nut
3 Cushion rod nut Drive chain control mounting bolt Throttle lever case bolt Clutch lever hold mounting bolt TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or "4" marked bolt 7" marked bolt 0 (mm) N m kgfm lbft N m kgfm lbft Conventional bolt "4" marked bolt "7" marked bolt
4 SERVICE DATA VALVE + GUIDE Unit: mm (in) Valve diam. 36 IN. (1.42) 29 EX. (1.14) Tappet clearance (when cold) IN ( ) EX ( ) Valve guide to valve stem IN clearance ( ) EX ( ) Valve stem deflection 0.25 IN. & EX. (0.010) Valve guide I.D. IN. & EX ( ) Valve stem O.D IN. ( ) EX ( ) Valve stem runout 0.05 IN. & EX. (0.002) Valve head thickness IN. & EX. 0.5 (0.02) Valve seat width IN. & EX ( ) Valve head radial runout 0.03 IN. & EX. (0.001) Valve spring free length 34.0 IN. (1.34) 33.3 EX. (1.31) Valve spring tension N IN. ( kgf, Ibs) at length 30.9 mm (1.22 in) 78.5 N EX. (7.85 kgf, 17.3 Ibs) at length 30.9 mm (1.22 in)
5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) Cam heigh IN. ( ) (1.2702) EX ( ) (1.3052) Camshaft journal oil clearance IN. & EX. ( ) (0.0059) Camshaft journal holder I.D. N. IN & EX ( ) Camshaft journal O.D. IN. & EX ( ) Cam chain pin 15th pin Cylinder head distortion 0.05 (0.002) CYLINDER + PISTON + PISTON RING Unit: mm (in) Compression pressure 800 kpa (Automatic decomp. actuated) (8.0 kgf/cm2, 114 psi) Piston to cylinder clearance ( ) (0.0047) Cylinder bore Nicks or ( ) Scratches Piston diam ( ) (3.7551) Measure at 10 mm (0.6 in) from the skirt end. Cylinder distortion 0.05 (0.002) Piston ring free end gap 1st Approx. 7.6 (0.30) 2nd R Approx (0.48) Piston ring end gap st ( ) (0.020) nd ( ) (0.020) Piston ring to groove clearanc 1 st (0.007) 2nd (0.006) Piston ring groove width ( ) 1st ( ) 2nd ( ) Oil ( )
6 Piston ring thickness ( ) 1st ( ) nd ( ) Piston pin bore ( ) (0.7492) Piston pin O.D ( ) (0.7472) CONROD + CRANKSHAFT Unit: mm (in) Conrod small end I.D ( ) (0.7496) Conrod deflection 3.0 (0.12) Conrod big end side clearance ( ) 1.0 (0.04) Conrod big end width ( ) Crank web to web width 62.0 ± 0.1 (2.441 ± 0.004) Crankshaft runout 0.08 (0.003) OIL PUMP Oil pressure (at 60 C, 140 F) 10 kpa (0.1 kgf/cm2, 1.4 psi) at r/min CLUTCH Unit: mm (in) Clutch cable play ( ) Drive plate thickness (No. 1 & No. 2) ( ) (0.109) Drive plate claw width (No. 1 & No. 2) ( ) (0.528) Driven plate distortion 0.10 (0.004) Clutch spring free length (2.09) (1.98)
7 DRIVE TRAIN + DRIVE CHAIN Unit: mm (in) Except ratio Primary reduction ratio (77/27) Final reduction ratio (36/14) Gear ratios Low (27/13) 2nd (28/17) 3rd (28/21) 4th (23/21) Top (21/23) Shift fork to groove clearance ( ) 0.5 (0.020) Shift fork groove width No.1, No & No.3 ( ) Shift fork thickness No.1, No.2 & No ( ) Drive chain Type RK 520SMOZ1OS Links 96 20pitch length (12.57) Drive chain slack ( ) Gearshift lever height 5 10 ( ) THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper Approx C (169.7 F) _ ature Thermostat valve lift 4.5 mm (0.18 in) and over at 90 C (194 F) ECT sensor resistance 20 C Approx. 2.6 ki2 (68 F) 50 C Approx ks2 (122 F) 80 C (176 F) Approx kf2 110 C (230 F) Approx kci Radiator cap valve opening pres kpa sure ( kgf/cm2, psi) Cooling fan operating temperature OFF ON Approx. 98 C (208 F) ONDOFF Approx. 93 C (199 F) Engine coolant type Use an antifreeze/coolant compatible with alumi num radiator, mixed with distilled water only, at the ratio of 50:50. Engine coolant including reserve Approx ml ( US/Imp qt)
8 INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM SPECIFICATION NOTE Injector resistance 9 17 Q at 20 C (68 F) Fuel pump discharge amount Approx. 83 ml (2.8/ 2.9 US/Imp oz) and more /10 sec. Fuel pressure regulator operating set pressure Approx. 294 kpa (2.94 kgf/cm2, psi) Fl SENSORS ITEM SPECIFICATION NOTE CKP sensor resistance Q CKP sensor peak voltage 0.5 V and more When cranking IAP sensor input voltage V IAP sensor output voltage Approx. 2.7 V at idle speed TP sensor input voltage V TP sensor resistance Approx. 4.5 kq Closed Approx. 1.4 kq Opened Approx. 4.2 IcS2 TP sensor output voltage Closed Approx. 0.6 V Opened Approx. 3.8 V ECT sensor input voltage V ECT sensor output voltage V ECT sensor resistance Approx. 2.6 kq at 20 C (68 F) IAT sensor input voltage V IAT sensor output voltage V IAT sensor resistance Approx. 2.6 Id2 at 20 C (68 F) TO sensor resistance ks2 TO sensor voltage Normal V Leaning V n Whe leaning 65 GP switch voltage 0.9 V and more From 1st to Top Injector voltage Battery voltage Ignition coil primary peak voltage 150 V and more When cranking THROTTLE BODY ITEM SPECIFICATION Bore size 43 mm I.D. No. 45G0 Idle r/min ± 100 r/min Idle air screw 15/8 turns back Throttle cable play 3 5 mm ( in) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug Type NGK: CR8EB Gap ( ) Spark performance Over 8 (0.3) at 1 atm. CKP sensor resistance Q
9 ITEM SPECIFICATION NOTE CKP sensor peak voltage 0.5 V and more When cranking Ignition coil resistance Primary Q Terminal Terminal Secondary 8 15 kl2 cap Plug Terminal Ignition coil primary peak voltage 150 V and more When cranking Generator coil resistance Q Generator Max. output Approx. 240 W at r/min Generator noload voltage 50 V (AC) and more at r/min (When engine is cold) Starter motor bursh length Standard 7.0 (0.28) Limit 3.5 (0.14) Regulated voltage V at r/min Starter relay resistance 3 6 Q GP switch voltage 0.9 V and more (From 1st to Top) Battery Type FTX7ABS designation Capacity 12 V 21.6 kc (6 Ah)/10 HR Fuse size Ignition 10 A Fan 10 A Main 20 A WATTAGE Unit: W ITEM SPECIFICATION Headlight HI 40 LO 40 Brake light/taillight LED Fuel indicator light 3.4 Neutral indicator light 3.4 Engine coolant temp. Fl warning 3.4 indicator light BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake pedal height 0 10 Brake caliper cylinder bore (0 0.4) Front ( ) Rear ( ) Brake caliper piston diam. Front ( ) Rear ( ) Brake fluid type DOT 4 Brake disc thickness Front ( ) Rear ( ) (0.098) 3.5 (0.138)
10 ITEM SPECIFICATION NOTE Brake disc runout (Front & Rear) 0.30 (0.012) Master cylinder bore Front ( ) Rear ( ) Master cylinder piston diam. Front ( ) Rear ( ) Turning radius 3.5 m (11.5 ft) Toein (with 75 kg, 165 Ibs) 0 ± 4 (0 ± 0.16) Camber 3.0 Caster 8.0 Wheel rim runou Front 2.0 (0.08) Rear 2.0 (0.08) Wheel rim size Front 10 x 5.5 AT Rear 8 x 8.0 AT Tire size Front AT20 x 7R10 '** Rear AT18 x 10R8 *** Tire type Front DUNLOP: KT381 Rear DUNLOP: KT385 Tire tread dept Front 4.0 (0.16) Rear 4.0 (0.16) Wheel axle runou Rear 6.0 (0.24) TIRE PRESSURE COLD INFLATION kpa kgf/cm2 psi TIRE PRESSURE FRONT REAR VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 Ibs) SUSPENSION ITEM STANDARD/SPECIFICATION LIMIT Front shock absorber spring preset length (10.8) Front shock absorber damping Rebound 11/2 turns out from stiffest position force adjuster Compressi 21/4 turns out from stiffest position on Rear shock absorber spring preset 299 length (11.8)
11 ITEM STANDARD/SPECIFICATION LIMIT Rear shock absorber damping Rebound 7 clicks out from stiffest position force adjuster Compressi 8 clicks out from stiffest position on (Low speed) Compressi 3/4 turn out from stiffest position on (High speed) Front wheel travel 254 (10.0) Rear wheel travel 277 (10.9) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2). Gasoline containing MTBE (Methyl Tertiary Butyl E28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 95 octane or Others higher. An unleaded gasoline is recommended. Fuel tank including reserve 10.0 L (2.6/2.2 US/Imp gal) Engine oil type SAE 10 W40, API SF/SG or SH/SJ with JASO MA Engine oil capacity Change ml (1.3/1.1 US/Imp qt) Oil tank side Filter change 400 ml Engine side (0.4/0.4 US/Imp qt) ml Oil tank side (1.4/1.1 US/Imp qt) Overhaul 400 ml (0.4/0.4 US/Imp qt) ml (1.5/1.2 US/Imp qt) 400 ml (0.4/0.4 US/Imp qt) Engine side Oil tank side Engine side
SERVICE DATA Date: August 1, 2007
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Valve + Valve Guide Unit: mm (in) Item Standard Limit Valve diam. IN (1.20) EX (1.06) Valve clearance (when cold)
Model: LT-A400FL9 P-17, 24, 28,03 Date: Feb. 12, 2018 SERVICE DATA Valve + Valve Guide Valve diam. IN. 30.6 (1.20) EX. 27.0 (1.06) Valve clearance (when cold) IN. 0.05 0.10 (0.002 0.004) EX. 0.22 0.27
SERVICE DATA. Unit: mm (in) ITEM STANDARD LIMIT Valve diam. IN (1.42) EX ( ) EX.
4 STROKE VALVE + VALVE GUIDE CAMSHAFT + CYLINDER HEAD SERVICE DATA Valve diam. 36.0 (1.42) 33.0 (1.30) Tappet clearance (when cold) 0.10 0.20 (0.004 0.008) 0.20 0.30 (0.008 0.012) Valve guide to valve
SERVICE DATA. Unit: mm (in) ITEM STD/SPEC. LIMIT Valve diam. 29 IN. (1.14) EX IN. ( ) EX.
4 STROKE VALVE + GUIDE SERVICE DATA Date: November 23, 2000 Valve diam. 29 (1.14) 24 (0.94) Valve clearance (when cold) 0.10 0.20 (0.004 0.008) 0.20 0.30 (0.008 0.012) Valve guide to valve stem 0.010 0.037
SERVICE DATA. Item Standard Limit Valve diam. IN (1.42) EX (1.30) Tappet clearance (When cold)
Model: LT-A750XK9 P-17, 24, 28, 33 LT-A750XZK9 P-17, 28, 33 4 STROKE Camshaft + Cylinder Head SERVICE DATA Valve + Guide Valve diam. IN. 36.0 (1.42) EX. 33.0 (1.30) Tappet clearance (When cold) IN. 0.10
Unit: mm (in) ITEM STANDARD LIMIT IN. 33 (1.3) EX.
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