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General Specifications
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheel base
Minimum ground clearance
Caster (steering head angle)
Trail
Weight:
185 kg (407 Ib)
Net
Engine:
Type
Bore x stroke x cylinders
Displacement
Compression ratio
Lubrication:
Lubrication
system
Pressure lubricated,
wet sump
Trochoid
Carburetion:
Manufacture
MIKUNI
Type
Ignition:
Type
Battery ignition
Spark plug
(Full transistor
ignition)
(NO)
Charging:
Type
Manufacture,
Maximum output
HITACHI,
14V 17A
L011703
Battery type
12N12A-4A
Battery dimensions
Regulator/Rectifier
Regulating voltage (No. load)
Starting:
14.2 -
14.8V
Electric starter
Primary drive:
Type
Teeth, ratio
Clutch:
Spur gear
22/21 x 68/25 (2.850)
Wet, multiple
disc
Transmission:
Type
Teeth, ratio
1st
41/15
2.733
2nd
3rd
37/19
34/22
1.947
1.545
4th
31125
5th
29/28
27/30
1.240
1.036
6th
0.900
Secondary drive:
Type
Chain
Teeth, ratio
45/16
2.813
Chassis:
Frame
Suspension:
Tires:
Brakes:
Telescopic fork
150 mm (5.91 in)
Swing arm, 100 mm (3.94 in)
Rear
3.00H194PR, Tubeless
110/9018 61H, Tubeless
Front
Single hydraulic
Rear
Drum brake
16 lit. (4.2 US. gal)
Fuel tank:
Total
Wheels:
Reserve
Front
Rear
disc
Maintenance specifications
1. Engine
Engine oil capacity:
Total amount
If temperature
5'c (40'F)
15'c (60F)
difference
between cylinders:
72
Camshafts:
Standard size
Dimensions
Intake
A
28.0 mm
(1.102 in)
7.80 mm (0307
Exhaust
35.1
mm(I.382in)
28.0
mm(I.102in)
7.1
mm (0.280 in)
24.967 -24.980
mm (0.9830-0.9835
in)
clearance:
0.020-
Maximum
0.160mm
0.054 mm (0.0008-
Inner
Intake/Exhaust
Allowable tilt
from vertical
-1I--
0.0021 in)
(0.006 in)
Valve springs:
1.6mm
Outer
Outer
Intake/Exhaust
Free length
Spring rate
2.429 kg/mm
(136.0Ib/in)
4.726 kg/mm
(264.7Ib/in)
Installed length
(valve closed)
Installed pressure
(valve closed)
18.5 kg (40.8Ib)
Compressed langth
(valve open)
Wire diameter
Number of windings
7.6
6.0
19.9 +g.3 mm
0
28.3-0.3
Winding 0.0.
012
(0.783+g
Intake
in)
Standard
Outer
Wear limit
in)
mm
Exhaust
Valves:
Valve stem run-out maximum
Valve seat width standard/maximum
INTAKE
Clearance
(Cold engine)
0.11-0.15
mm
(0.004-0.006
in)
30 0.1 mm
(1.1811 0.0039
1.0t 0.1 mm
(0.0394 0.0039 in)
1.2 0.2 mm
(0.04 72 0.0079 in)
in)
-0.010
6 -0.025 mm
-00004
(0.2362 -0:0010 in)
6+0012 mm
0
(0.2362 +g.0005 in)
Stemtolluide
0.010~0.037 mm
(0.0004-0.0015 ln]
Y"S"
clearance
EXHAUST
~"C"
}
Clearence
(cold engine)
0.16-0.20 mm
(0.006-0.008 in)
260.1 mm
(1.024 0.0039 in)
"S"face width
1.0 0.1 mm
(0.0394 0.0039 in)
1.00.2 mm
(0.0392 0.0079 in)
6-0025
m
-0.040 m
-0.0010
(0.2362 -0.0016 Inl
6 +0.012 mm
0
(0.2362 +g.0005
0.025-0.052 mm
(0.0010- 0.0020 inl
Stemt01luide clearance
Cylinder
in]
and piston:
Cylinder
material
Aluminum
Cylinder
liner
Bore size:
standard
wear limit
Cylinder
taper limit
Cylinder
out-of-round
Piston clearance:
alloy
standard
maximum
Piston rings:
Top
2nd
Design
Barrel
Taper
standard
0.15-0.35
mm
(0.00590.0138 in)
limit
Side clearance:
1.0mm
(0.0394 in)
0.03-0.07
standard
mm
(0.0012-
limit
7-4
0.0018 in)
Oil
Expander
0.15-0.35
mm
(0.00590.0138 in)
1.0mm
(0.0394 in)
0.02-0.06
(0.008-
0.3-0.9mm
(0.0118 0.035 in)
1.5 mm
(0.0591 in)
mm
0.0028 in)
0.0024 in)
0.15 mm
(0.0059 in)
0.15 mm
(0.0059 in)
Crankshaft:
Crank journallbearing
Main journal run-out
oil clearance
(maximum)
0.040-0.064
mm (0.0016-0.0025
in)
Connecting rods
Rod bearing oil clearance
0.03 -0.09
mm (0.0012-0.0035
in)
Oil pump:
Housinq-to-outer rotor clearance
Outer rotor-to-inner rotor clearance
0.0059 in)
0.0035 in)
Clutch:
Frictionpplate:
thickness/q'ty
Clutch plate:
minimum thickness
thickness
warp limit
length/q'ty
Clutch spring:
minimum length
spring rate
Clutch lever free play (at lever pivot point)
LUBRICATION
in)
CHART
2. Carburetion
Manufacturer
MIKUNI
Fuel level
4U800
Preset
Main jet
Pilot screw
Air jet, Main
Needle jet
Pilot jet
08
# 35
170
130
Starter jet
Jet needle
# 35
4GZ11
112.5
Throttle
(11
0.7)
3. Chassis
70
tP 2.0
1,200 r/min
'Total
valve
#
#
#
horizontal
Front
kg/cm1
Rear
(26 psi)
Minimum
-192
kg (423Ib)
load"
(Maxim~;n
load
Brakes:
Recommended fluid
DOT # 3
6.8 mm (0.27 in)
standard
4 mm (0.16 in)
wear limit
2 mm (0.08 in)
0.3 in)
20-
1.2 in)
thickness
30 mm (0.8 -
Front forks:
150 mm (5.91 in)
508 mm (20.00 in)
Travel
Spring free length
Spring preload length
Spring rate:
0-105
105-150
mm (4.13-5.91
Fork oil capacity (each side)
Oil type
Rear shock absorber:
Spring free length
Spring preload length
0-36
mm (0-1.42
Spring rate:
36 Travel
80mm(1.42-3.15in)
4. Electrical
Spark plug:
Electrode gap
10Kn
Pick up coil:
Resistance
6S0n
HITACHI CM1210
2.Sn 10% at 20C (68F)
11kn 20% at 20C (stF)
MITSUBA SM-8204
0.012n 6% at 20C (6SoF)
12.0 mm (0,472 in)
S.O mm (0.20 in)
400 60g (14.0S 2.11 oz)
O.S mm (0.031 in)
1-.
Battery type:
Charging rate
G.S.12N12A4A
1.2 Amps for 10 Hours
Generator type:
Output
Field (inner) coil resistance
Stator (outer) coil resistance
HITACHI L011703
14V17A at S,OOOrlmin
4.Sn 10% at 20C (stF)
o.sn 10% at 20C (68F)
Regulator type:
Regulated voltage
Allowable amperage
I.C. (SSS15)
14.5 0.3V
4A
HONDA LOCK
SV
Headlight:
Tail/brake light:
Flasher light:
Pilot lights:
TURN
HIGH BEAM
NEUTRAL
OIL LEVEL
Meter light
12V, SOW/40W
12V, SW (3CP)/27W (32CP) x 2
12V, 27W (32CP) x 4
12V, 3.4W
12V, 3,4W
12V. 3.4W
12V, 3.4W
12V.3,4W
x
x
x
x
x
2
1
1
1
2
Tightening
torque
Tightening
Part name
torque
Q'ty
Thread size
Remarks
m-kg
ft-lb
ENGINE:
Bolt
M6 x 1.0
24
1.0
7.2
Tighten
Stud bolt
M6 x 1.0
0.5
3.6
Apply oil
Stud bolt
M6 II 1,0
1.0
7.2
Apply oil
Cylinder head
Stud bolt
M8 x 1.25
1.5
11.0
Apply oil
Cylinder head
Nut
M8 x 1.25
2.0
14.5
Cylinder head
Cap nut
M8 x 1.25
12
2.2
16.0
M12xl.25
2.0
14.5
Bolt
M6 x 1.0
12
1.0
7.2
Bolt
M6 x 1.0
1.0
7.2
Stud bolt
M8 x 1.25
1.5
11.0
Plug
M12 x 1.25
2.2
16.0
Nut
M8 x 1.25
2.0
14.5
Cylinder
Nut
M6 x 1.0
1.0
7.2
Nut
M7 x 0_75
2.5
18.0
Bolt
M7 x 1.0
2.0
14.5
Bolt
M6 x 1.0
0.6
4.3
Bolt
M6 x 1.0
1.0
7.2
Nut
M6 x 1.0
1.0
7.2
Nut
M8 x 1.25
0.9
6.5
Crankcase
Plug
M10xl.25
1.0
7.2
Screw
M6 x 1.0
0.7
5.1
Screw
M6 x 1.0
0.7
5.1
Bolt
M6 x 1.0
1.0
7.2
Bolt
M6 x 1.0
12
1.0
7.2
Union bolt
M20 x 1.5
1.5
11.0
Plug
M14 x 1.5
4.3
31.0
Bolt
M6 x 1.0
1.0
7.2
Screw
M5 x 0.8
0.5
3.6
Bolt
M6 x 1.0
0.7
5.1
Nut
M6 x 1.0
1.0
7.2
Bolt
M8 x 1.25
2.0
14.5
Muffler
Bolt
Ml0xl.25
2.5
18.0
Muffler protector
Bolt
Ml0xl.25
2.5
18.0
Muffler protector
Screw
M6 x 1.0
0.7
5.1
rSpark
plug
Cylinder
--
head cover
in 3-stages
Apply oil
I-
Cylinder
Cylinder
rs
--
trainer cover
--
head
7-8
Apply oil
..
Part to be tightened
Part name
Thread size
O'ty
Tightening
torque
Remarks
mkg
ft-lb
Crankcase
Stud bolt
MB x 1.25
12
1.3
9.5
Apply oil
Bolt
MB x 1.25
11
2.4
17.5
Apply oil
Bolt
M6 x 1.0
23
1.2
B.5
Apply oil
Bolt
M6 x 1.0
1.0
7.2
Bolt
M6 x 1.0
1.0
7.2
Screw
M6 x 1.0
1.0
7.2
Screw
M6 x 1.0
1.0
7.2
Crankcase cover
Bolt
M6 x 1.0
13
1.0
7.2
Plug
M20 x 1.5
1.2
B.5
Bolt
M6 x 1.0
O.B
5.B
Clutch boss
Nut
M20 x 1.0
7.0
50.5
Drive sprocket
Bolt
M6 x 1.0
1.0
7.2
Cam shift
Screw
M5 x O.B
0.7
5.1
Stopper plate
Bolt
M6 x 1.0
1.0
7.2
Change pedal
Bolt
M6 x 1.0
1.0
7.2
A.C. Generator
Bolt
Ml0 x 1.25
3.5
25.5
Screw
M6 x 1.0
O.B
5.B
Bolt
MB x 1.25
2.4
17.5
Screw
M6 x 1.0
O.B
5.B
Timing plate
Screw
M6 x 1.0
O.B
5.B
Starter motor
Bolt
M6 x 1.0
1.0
7.2
Neutral switch
Screw
M5 x O.B
0.3
2.2
Bolt
M6 x 1.0
0.7
5.1
7-9
Use LOCKTITE
Apply oil
Use LOCKTITE
.Use LOCKTITE
Part to be tightened
Part name
Thread size
Q'W
Tightening
torque
Remarks
rn-kq
ftlb
CHASSIS:
Front, upper
Nut
Ml0
Pl.25
4.2
30.5
Front, under
Rear, under
Bolt
Nut
MID
M12
Pl.25
Pl.25
2
1
4.2
7.0
30.5
50.5
Engine .
~IFron t
Mounting Stay
Bolt
MS
Pl.25
2.0
14.5
Bolt
M14
Pl.25
5.4
39.0
Nut cap
MS
Pl.25
2.0
14.5
Bolt
MS
Pl.25
2.0
14.5
Bolt
M12
Pl.25
3.S
27.5
Nut Castle
M14
Pl.5
10.5
76.0
MS
P1.25
2.0
14.5
Engine
Mounting
Bolt
Handle crown&Handlebar
holder
Front wheel
Nut salf
locking
Pivot shaft
Nut
M14
Pl.5
9.0
65.0
Nut castle
M14
P1.5
10.5
76.0
Sprocket wheel
Nut
Ml0
Pl.25
6.2
45.0
Nut cap
MID
Pl.25
3.0
21.5
Bolt
M10
Pl.25
3.0
21.5
7.0
50.5
Footrest
Bolt
M12
Pl.25
Bolt
MS
Pl.25
2.0
14.5
Bolt
MS
P1.25
2.0
14.5
Bolt
M6
Pl.0
0.9
6.5
Bolt
MS
P1.25
12
2.0
14.5
Bolt union
M10
Pl.25
2.6
19.0
Bolt union
MID
P1.25
2.6
19.0
Bolt union
M10
P1.25
2.6
19.0
MID
Pl.25
4.5
32.5
MS
Pl.25
0.6
4.3
Front fender
Bolt
MS
Pl.25
1.0
7.2
Screw
M5
PO.S
O.lS
1.3
Muffler
Bolt
Ml0
Pl.25
4.2
30.5
Bolt
MID
Pl.25
4.5
32.5
Master cylinder
Master cylinder
Bolt
M6
Pl.0
0.9
6.5
Nut
M25
Pl.0
3.S
27.5
Bolt
M6
P1.0
0.9
6.5
Bolt
M6
P1.0
0.5
3.6
Bolt
M6
Pl.0
0.6
4.3
&
bracket
7 10
Lock washer