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Dimensions
Length: 2255 mm (88.8 in)
Width: 825 mm (32.5 in)
Height: 1245 mm (49.0 in)
Wheelbase: ED, DK – 1425 mm (56.1 in), U – 1490 mm (58.7 in)
Seat Height: 939 mm (37.0 in)
Ground Clearance: 305 mm (12.0 in)
Dry Weight: ED, DK – 131.0 kg (289 lbs), U – 133.0 kg (293 lbs)
Curb Weight: ED, DK – 142.0 kg (313 lbs), U – 144.0 kg (317 lbs)Frame
Frame Type: Semi-double cradle
Front Suspension: Telescopic fork
Front Wheel Travel: 285 mm (11.2 in)
Rear Suspension: Swingarm
Rear Wheel Travel: 307 mm (12.1 in)
Front Tyre (Tire) Size: 3.00-21 51P
Rear Tyre (Tire) Size: 4.50-18 70P
Tyre (Tire) Brand FR/RR: TR8/TR8 (IRC)
Front Brake: Hydraulic single disc
Rear Brake: Hydraulic single disc
Caster Angle: 27 degrees 32′
Trail Length: 108 mm (4.3 in)
Fuel Tank Capacity: 10.0 l (2.64 US Gal, 2.2 Imp Gal)
Fuel Tank Reserve Capacity: 4.5 l (1.19 US Gal, 0.99 Imp Gal)Engine
Type: Petrol (Gasoline), liquid cooled 4-stroke SOHC
Cylinder Arrangement: Single cylinder inclined 13 degrees
Bore and Stroke: 100.0 x 82.6 mm (3.94 x 3.25 in)
Displacement: 649 cm cubed (39.6 cu-in)
Compression Ratio: 10.0:1
Valve Train: 4-valve, single chain driven SOHC
Intake Valve Opens: 15 degrees BTDC
Intake Valve Closes: 45 degrees ABDC
Exhaust Valve Opens: 45 degrees BBDC
Exhaust Valve Closes: 15 degrees ATDC
Lubrication System: Forced pressure and dry sump
Oil Pump Type: Trochoid/double rotor
Cooling System: Liquid cooled
Air Filtration: Oiled polyurethane foam
Engine Weight: 40.9 kg (90.2 lbs)Carburettor (Carburetor)
Carburettor (Carburetor) type: Piston valve
Throttle Bore: 42 mm (1.7 in)Drive Train
Clutch System: Multi-plate, wet
Clutch Operation System: Cable operating
Transmission: Constant mesh, 5 speeds
Primary Reduction: 1.651 (71/43)
Final Reduction:
ED, DK – 3.429 (48/14)
U – 2.733 (41/15)
Gear Ratio 1st: 3.083 (37/12)
Gear Ratio 2nd: 2.125 (34/16)
Gear Ratio 3rd: 1.666 (30/18 )
Gear Ratio 4th: 1.333 (28/21)
Gear Ratio 5th: 1.115 (29/26)
Gearshift Pattern: Left operated return system 1 – N – 2 – 3 – 4 – 5Electrical
Ignition System: CDI (Capacitive Discharge Ignition)Lubrication System
Engine Oil Capacity:
at draining 1.56 l (1.65 US qt, 1.37 Imp qt)
at disassembly 2.0 l (2.1 US qt, 1.8 Imp qt)
at filter change 1.6 l (1.7 US qt, 1.4 Imp qt)
Recommended Engine Oil: Honda 4-stroke oil or equivalent motor oil. API service classification: SE, SF or SG Viscosity.
Oil Pump Rotor:
Tip clearance: 0.15 (0.006)
Body clearance: 0.15 – 0.22 (0.006 – 0.009)
Side clearance: 0.03 – 0.08 (0.001 – 0.003)
Fuel System
Carburettor Identification Number:
ED, DK: PE78C
U: PE78D
Main Jet:
ED, DK: #165
U: #112
Slow Jet: #65
Jet Needle Clip Position: 3rd groove from top
Pilot Screw Opening: Factory setting 1 3/4 turns out
Float Level: 18.0 mm
Idle Speed: 1400 +/- 100 rpm
Throttle Grip Free Play: 2 – 6 mm (1/16 – 1/4 in)Cooling System
Coolant Capacity:
Radiator and engine: 1.52 l (1.61 US qt, 1.34 Imp qt)
Reserve tank: 0.20 l (0.21 US qt, 0.18 Imp qt)
Radiator Cap Relief Pressure: 108 – 137 kPa (1.1 – 1.4 kgf/cm squared, 16 – 20 psi)
Thermostat:
Begins to open: 80 – 84 degrees C (176 – 183 degrees F)
Fully open: 95 degrees C (203 degrees F)
Valve Lift: 8mm (0.3 in) minimum
Standard Coolant Concentration: 50% mixture with soft waterCylinder Head / Valves
Decompressor Lever Free Play: 5 – 8 mm (3/16 – 5/16 in)
Cylinder Compression:
Valve clearance at standard (decompressor applied): 600 kPa (6.12 kgf/cm squared, 87 psi) at 400 rpm
Valve clearance at 1 mm (0.04 in) (decompressor not applied): 1100 kPa (11.22 kgf/cm squared, 160 psi) at 400 rpm
Valve Clearances:
IN: 0.15 +/- 0.02 (0.006 +/- 0.001 )
EX: 0.20 +/- 0.02 (0.008 +/- 0.001 )
Clutch
Clutch Lever Free Play: 10 – 20 (3/8 – 3/4)
Clutch Spring Free Length: 49.0 (1.93)
A (6 Discs): 45.5 (1.79) Service Limit – 44.5 (1.75)
43.2 (1.70) Service Limit – 41.6 (1.64)
Clutch Disc Thickness:
A (6 Discs): 3.22 – 3.38 (0.127 – 0.133) Service Limit 3.00 (0.118 )
B (1 Disc): 2.92 – 3.08 (0.115 – 0.121) Service Limit 2.69 (0.106)
Clutch Plate Warpage Service Limit: 0.30 (0.012)Front Wheel / Suspension / Steering
Cold Tyre (Tire) Pressure: 175kPa (25 psi)
Front Wheel Rim Runout Service Limit: Radial 2.0 (0.8 ), Axial 2.0 (0.8 )
Fork Spring Free Length: 506 (19.9) Service Limit 496 (19.5)
Fork Tube Runout Service Limit: 0.20 (0.01)
Recommended Fork Oil: Pro Honda Suspension Fluid SS – 7
Fork Oil Level: 120 (4.7)
Fork Oil Capacity: 637 cc
Compression damping adjuster standard position: 11 clicks out from full in
Rebound damping adjuster standard: 9 clicks from full inRear Wheel / Suspension
Cold Tyre (Tire) Pressure: 125 kPa (18 psi)
Rear Wheel Rim Runout Service Limit: Radial 2.0 (0.8 ), Axial 2.0 (0.8 )
Drive Chain Slack: 20 – 30 (13/16 – 1 3/16)
Drive Chain Length (at 41 pins / 40 links) Service Limit: 638 (25.1)
Drive Chain Size / Link:
ED, DK: DID 520VM-110LE or RK520KZO-110LE
U: DID 520VM-108LE or RK520KZO-108LE
Compression damping adjuster standard position: 6 – 10 clicks out from full in
Rebound damping adjuster standard position: 11 – 15 clicks out from full inDisc Brakes
Specified Brake Fluid: Dot 4
Brake Disc Thickness:
ED, DK: 2.8 – 3.2 (0.11 – 0.13) Service Limit 2.5 (0.10)
U: 3.3 – 3.7 (0.13 – 0.15 ) Service Limit 3.0 (0.12)
Brake Disc Runout: Service Limit 0.20 (0.008 )Electrical System
Spark Plug:
Standard Riding: NGK BKR7E-11, DENSO K22PR-U11
High Speed Riding: NGK BKR8E-11, DENSO K24PR-U11
Spark Plug Gap: 1.0 -1.10 (0.039 – 0.043 )
Headlight Bulb: 12 V 35/35 W
Taillight Bulb: 12V 21/5 WTorque Values
Unless specified all bolts should be tightened to the following torque values.
Standard Fasteners N-m (kgf-m, lbf-ft):
5 mm Bolt and Nut: 5 (0.5, 3.6)
6 mm Bolt and Nut: 10 (1, 7)
8 mm Bolt and Nut: 22 (2.2, 16)
10 mm Bolt and Nut: 34 (3.5, 25)
12 mm Bolt and Nut: 54 (5.5, 40)
5 mm Screw: 4 (0.4, 2.9)
6 mm Screw: 9 (0.9, 6.5)
6 mm Flange Bolt (8 mm Head: Small Flange): 9 (0.9, 6.5)
6 mm Flange Bolt (8 mm Head: Large Flange – engine only): 12 (1.2, 9)
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)
Engine N-m (kgf-m, lbf-ft):
Valve Adjust Cover Hole Bolt 4 x 6 mm: 12 (1.2, 9)
Oil Drain Bolt (at crankcase) 1 x 12 mm: 25 (2.5, 18 )
Valve Adjusting Lock Nut 4 x 8 mm: 25 (2.5, 18 )
Spark Plug 1 x 14 mm: 18 (1.8, 13)
Oil Pump Plate Bolt 2 x 6 mm: 12 (1.2, 9)
Water Pump Assembly Bolt 2 x 6 mm: 13 (1.3, 9)
Thermostat Housing Cover Bolt 2 x 6 mm: 12 (1.2, 9)
Cylinder Head Nut 4 x 10 mm: 44 (4.5, 33) NOTE 4
Head Cover Bolt 2 x 8 mm: 23 (2.3, 17)
Head Cover Bolt 8 x 6 mm: 12 (1.2, 9)
Cam Sprocket Bolt 2 x 7 mm: 20 (2.0, 14) NOTE 1
Cam Chain Tensioner Bolt 2 x 6 mm: 12 (1.2, 9) NOTE 1
Cylinder Bolt 2 x 6 mm: 12 (1.2, 9)
Kickstarter Pedal Pinch Bolt 1 x 8 mm: 37 (3.8, 27)
Flywheel Bolt 1 x 12 mm: 127 (13.0, 94) NOTE 4
Left Crankcase Cover Stud Bolt 4 x 6 mm: 12 (1.2, 9)
Timing Hole Cap 1 x 14 mm: 10 (1.0, 7)
Frame N-m (kgf-m, lbf-ft):
Exhaust Pipe Joint Nut 4 x 8 mm: 18 (1.8, 13)
Exhaust Pipe Clamp Bolt 1 x 8 mm: 20 (2.0, 14)
Muffler Mounting Bolt 2 x 8 mm: 32 (3.3, 24)
Muffler Clamp Bolt 1 x 8 mm: 20 (2.0, 14)
Muffler Mounting Bolt 2 x 8 mm: 32 (3.3, 24)
Exhaust Pipe Protector Bolt 2 x 6 mm: 12(1.2, 9)Maintenance N-m (kgf-m, lbf-ft):
Fuel Valve Mounting Bolt 2 x 6 mm: 9 (0.9, 6.5)
Down tube Oil Drain bolt 1 x 8 mm: 39 (4.0, 29)
Rear Brake Pedal Adjuster Lock Nut 1 x 8 mm: 18 (1.8, 13)
Side Stand Pivot Nut 1 x 10 mm: 39 (4.0, 29)
Spark Arrestor Bolt 3 x 6 mm: 12 (1.2, 9)
Rim Lock 2 x 8 mm: 13 (1.3, 9)
Lubrication N-m (kgf-m, lbf-ft):
Down Tube Oil Strainer 1 x 27 mm: 54 (5.5, 40)
Oil inlet Pipe Bolt 1 x 12 mm: 37 (3.8, 27)
Front Wheel / Suspension / Steering N-m (kgf-m, lbf-ft):
Front Brake Disc Bolt 4 x 6 mm: 20 (2.0, 14) NOTE 1
Front Axle 1 x 16 mm: 88 (9.0, 65)
Front Axle Holder Nut 4 x 6 mm: 12 (1.2, 9) NOTE 5
Fork Center Bolt 2 x 27 mm: 54 (5.5, 40) NOTE 1
Fork Cap Bolt 2 x 43 mm: 30 (3.1, 22)
Steering Stem Nut 1 x 24 mm: 98 (10.0, 72)
Rear Wheel / Suspension / Steering N-m (kgf-m, lbf-ft):
Rear Brake Disc Bolt 4 x 6 mm: 20 (2.0, 14) NOTE 1
Rear Axle Nut 1 x 16 mm: 93 (9.5, 69) NOTE 5
Driven Sprocket Nut 6 x 8 mm: 42 (4.3, 31) NOTE 5
Swingarm Pivot Nut 1 x 18 mm: 108 (11.0, 80) NOTE 5
Shock Absorber Upper Mounting Nut 1 x 10 mm: 44 (4.5, 33) NOTE 5
Shock Absorber Lower Mounting Nut 1 x 10 mm: 44 (4.5, 33) NOTE 5
Shock Arm-to-Swingarm Nut 1 x 12 mm: 78 (8.0, 58 ) NOTE 5
Shock Link-to-Shock Arm Nut 1 x 12 mm: 69 (7.0, 51) NOTE 5
Shock Link Nut 1 x 12 mm: 69 (7.0, 51) NOTE 5
Shock Absorber Spring Lock Nut 1 x 56 mm: 29 (3.0, 22)
Swingarm Pivot Lock Nut 1 x 28 mm: 64 (6.5, 47)
Side Stand Mounting Bolt 1 x 8 mm: 26 (2.7, 20)
Side Stand Mounting Bolt 2 x 10 mm: 39 (4.0, 29)
Hydraulic Brake N-m (kgf-m, lbf-ft):
Brake Hose Oil Bolt 4 x 10 mm: 34 (3.5, 25)
Brake Lever Pivot Bolt/Nut 1/1 x 6 mm: 6 (0.6, 4.3)
Brake Lever Adjuster Lock Nut 1 x 5 mm: 6 (0.6, 4.3)
Front Caliper Mounting Bolt 2 x 8 mm: 29 (3.0, 22) NOTE 1
Caliper Bleed Valve 2 x 8 mm: 6 (0.6, 4.3)
Rear Master Cylinder Mounting Bolt 2 x 6 mm: 12 (1.2, 9)
Pad Pin 2 x 10 mm: 18 (1.8, 13)
Pad Pin Plug 2 x 10 mm: 3.0 (0.3, 2.2 )
Front Caliper Pin Bolt 1 x 8 mm: 23 (2.3, 17) NOTE 1
Front Caliper Bracket Pin Bolt 1 x 8 mm: 23 (2.3, 17) NOTE 1
Rear Caliper Pin Bolt 1 x 12 mm: 27 (2.8, 20)
Rear Caliper Bracket Pin Bolt 1 x 8 mm: 13 (1.3, 9) NOTE 1
Brake Pdeal Pivot Bolt 1 x 8 mm: 25 (2.6, 19)
Rear Master Cylinder Push Rod Lock Nut 1 x 8 mm: 18 (1.8, 13)NOTE 1: Apply locking agent to the threads.
NOTE 2: Apply grease to the threads and seating surface.
NOTE 3: Stake.
NOTE 4: Apply oil to the threads and seating surface.
NOTE 5: U-nutMight need to make this a sticky
Ollie
Ollie wrote:Might need to make this a sticky
Ollie
Already did!
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