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    MANUAL DE SERVICIO HERO HUNK 160FI

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    01_GENERAL INFORMATION-I

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    MANUAL DE SERVICIO HERO HUNK 160FI

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    Download as pdf
    42 views37 pages

    01 - General Information-I

    Uploaded by

    kamil motors
    MANUAL DE SERVICIO HERO HUNK 160FI

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    AAFEW WORDS ABOUT SAFETY SERVICE INFORMATION he service and repairinformation contained inthis manvalis 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 domage 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 fo use o replacement pan, service procedure or a fool that is nol recommended by Hero MoioCorp, mus! determine the risks to their personal safely and the sofe operation ofthe vehicle. IV you need to replace « port, use genuine Hero MoteCorp parts withthe correct port number or an equivalent part. We strongly recommend that you do not use replacement port of inferior quality Peo FOR YOUR CUSTOMER'S SAFETY Proper service and maintenence are essential fo the customer’s safely and the Pimueeersernetttrapetan create on ‘alco heveice. Any ertororovesightwhe serving ovehile can esulln_ | IMB"OPe” sce ot repairs can create an faulty operation, damage to the vehicle, or injury to others. customer or others to be seriously hut or FORYOUR SAFETY Killed. Follow the procedures ond Because this manual s intended forthe p precautions in this manual and other provide warnings about many basic shop safely practices (e.g service materials carefully, gloves). Some of the most important general service safely precautions are given fessional service technician, we do nol Hot parts- wear below. However, we cannot war 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 PRECAUTION Make sure you have a clear understanding of all basic shop sofety practices and that you are wearing appropriate clothing and using safely equipment. When Feilure 10 properly follow insructions and precautions can cause you to be seriously hurtorkilled Follow the procedures and precautions in this manual careful performing any service task, be especially careful ofthe following + Read all ofthe instructions before you begin and make sure you have the tools, the replacement orrepair parts and the skils required to perform the tasks safely and completely. Protect your eyes by using proper sofety glosses, goggles or face shields ony time you hammer, drill, grind, pry or work around pressurized air orliquids ond springs or other stored- energy components. Ithere is any doubt, put on eye protection, Use other protective wear when necessary, for example gloves or sofety shoes. Handling hot or sharp paris can cause severe burns or cuts, Before you grab something thot lookslike it can hurt you, stop and puton 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 ajack, make sure that iis ays securely supported, Use jack stands. Make sure the engine is offbefore 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 runthe engine *+ Burns from hot pars, Letthe engine and exhaust system cool before working in those oreos, + Injury from moving oarts. the instruction tells you to run the engine, be sure your hands, fingers and clothing are out ofthe way. Gasoline vapors and hydrogen gases from batleries are explosive. To reduce the possiilily of « fire of explosion, be careful when working around gasoline or baleries. + Use only anonflammable solvent, no! gasoline, to clean ports, + Neverdrain orstore gasoline in an open container + Keep all cigarettes, sparks and flames away from the battery and allfuel- related ports. MEMO HOWTO USE THIS MANUAL This shop manvol describes the service procedures for HUNK. 160R PROGRAMMED Fi. Follow the Maintenence Schedule (Seetion 3) rocommendations roensure that the vehicles in peak operating condition. Performing the fist scheduled maintenance is vary impoctant. compensates for the intial wear that oceurs during the breakin period, Sections 1 and 3 opsly othe whole vehicle, Seetion 2 lisrotes procedures for removal/insllaion of components chat may be required to perform service described inthe following sections. Section 4 through 20 describe pars of the vehicle, grouped ‘ccording tolocation, TO LOCATE WHAT YOU ARE LOOKING FOR The tex ofthis manvalis divided into sections. 2. As the title ofthese sections is sted on the previous page ar GROUP INDEX, select the section where you ae looking for. 3. Holding the manualas shown ot the right wll allow you to find thefirst page of the section eas 4. On the first page ef each section, its contents ar listed. Find theitem ond page you need ENGINE & DRIVE TRAIN CONTENTS SECTION GENERAL INFORMATION |: | BODY PANELS/EXHAUST SYSTEM | 2 | MAINTENANCE El LUBRICATION SYSTEM |: | FUEL SYSTEM | 5 | ENGINE REMOVAL/INSTALLATION | | CYLINDER HEAD/VALVES | 7 | CYLINDER/PISTON |e | CLUTCH/GEARSHIFT LINKAGE/ KICK STARTER ALTERNATOR/STARTER CLUTCH J 10 | CRANKCASE/TRANSMISSION/ CRANKSHAFT FRONT WHEEL/SUSPENSION/STEERING [EES REAR WHEEL/BRAKE/SUSPENSION | 13 | You will find important safely information in © voriely of form] includ + SofelyLabels-onthe vehicle + Sofety Messoges- preceded by « solsty alert symbol and| ‘oneofttvee signal words, ANGER, WARNING or CAUTION, These signalwords mean. ‘You WIL be SERIOUSLY MURT you den SEE alow insnicions You CAN SERIOUSLY HURT you don NE clowinericiors. PITTI You CAN be HURT if you don’ follow instuctons. + lnsrvetions- howto sence this vehicle comectly ond safely CHASSIS TUBELESS TYRES J 14 | ANTI-LOCK BRAKING SYSTEM | 15 | HYDRAULIC BRAKE SYSTEM | 16 | BATTERY/CHARGING SYSTEM Ea IGNITION SYSTEM | 1s | ELECTRIC STARTER J 19 | ‘As you read this manvol, wil ind information that is preceded by © [NOTE] symbol. The purpose ofthis messogoisiohelpprovert damage ‘oyourvehicl,otherpronenyorthe ensironment TIL NFORWATION, ULUSTRATIONS, PHOTOGRAPIS, DIRECTIONS, SPECIFICATIONS AND OTHER CONTENTS COVERED IN THIS WORKSHO? MANUAL ARE BASED ON THE LATE uct INFORMATION AVAILABLE AT THE TM vA, AND THE ACCURACY OR COR! HE SAME IS. NOT UNDERTAKEN OR GUARANTEED. Here MoteCorp Limited 2ES°VES| THE RIGHT TO MAKE CHANGES IN IIS CONTENTS A ANY TIME WITHOUT NOTICE AND/OR INCURRING ANY O2LIGATION WHATSOEVER, NO ONE IS AILOWED TO REPRODUCE ANY PART OF THIS PUBLICATION WITHOUT OBTAINING PERMISSION ROM Here MoteCorp Limited. ELECTRICALS LAMPS/METERS/SWITCHES El WIRING DIAGRAM. El TROUBLESHOOTING Ei Vv Hero SYMBOLS SYMBOLS Listed in the table below ore the symbols indicating instructions and other information necessary for servicing ond meaning cossociated with them respectively SYMBOLS DESCRIPTION PDP —_[Peloce te ports) wih new one (before assembly Apply oil, Use engine cil unless otherwise specified, Use Molybdenum oll solution (Mixture of the engine oil and molybdenum grease in a ratio of 1:1) Apply grease Apply silicone grease, Apply moly paste bh A)A)O 80a cy Apply sealant Use fork cil Apply @ locking agent Apply or use brake fluid. [| Measure in voltage range. Measure in resistance range. Measure in cure range. Check for continuity Use special tool Torque control required, Dota beside it indicates specified torque. SYMBOLS Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning ‘associated with them respectively SYMBOLS DESCRIPTION " W s Feeler gauge J | Moma Decent] Crlinder bore gouge Dial gauge Vernier caliper MEMO Engine Torque Values Frame Torque Values GENERAL SERVICE PRECAUTIONS 1-15 General Service Precautions 1-1 General Torque Values 1-18 Model Identification 1-4 Lubrication & Seal Points 119 Specifications 1-5 Special Tools 1-25 Service Limit 1-7 n Control System 1-30 1-14 Cable/Wiring Harness/Tubes/Hoses Routing 1-32 1.GENERAL INFORMATION Always replace gos ;, O-rings, circlips and cotter pins with newones. O-RING. CAST COTTER PIN ciRCUP Ip i ff i When engine and final drive components are disassembled and inspected, coat the mating surface with alubricantto prevent corrosion When tightening nuts ond bolts, start first with the larger or centre ones. Tighten these to the specified torque using «criss-cross pattern ZZ rs Ig SS maxon \ oe After assembling components, use proper assembly lubricants Use only genuine Hero MotoCorp parts ond recommended lubricants. - “oe. ™~ AP 7 eee The VINis stamped on the right side of the steering head THROTTLE BODY IDENTIFICATION NUMBER. 1-4 GENERAL INFORMATION SPECIFICATIONS —GENERAL- TEM SPECIFICATIONS Overall lengih 2029 mm ‘Overall width 798 mm ‘Overall height TO52 mmr Dimensions| Wheelbose 1327 mm Saddle height 795 mm Kerb weight 138.5 kg (Dac Dron/139.5 kg [Dc D) Ground clearance 165 mm Frame type Tubular Diamond ype Front suspension Telescopic Fiydroule Front cushion stroke 130mm Reor suspension Monoshock Rear cushion stroke 39 mm Front tyre size 100/80 17 52 (Tubelessiyre) Rear fre size 130/70R17 62P (Radialtubeless lyre) ‘derony aoa 1.75 katen® (25 ps) a Rider onl TReor [1.96 kg F128 Rider & Pillion SM! 1.75 kaffem’ (25 psi) Rear 2.10 kaf/em® (30 psi) Front brake Disctype Dia. 276 mm Disc type Dio. 220 mm Reor broke Drom ype Dia. 130 mmm 72 lies (Minimum fuel fo be maintained above one Fuelionk capacity segment blinking of fuel level indicator) Casterengle 25.5 Trallengih 28mm Frontforkoll at disassembly 305 ce Tipe BV Ar cool Cylinder avrangement 15° inclined fol verical Maximum power Maximum torque Bore and stroke 37.3163.3 mm Displacement 163.23 cc | Compression ralio 38:1 Valve train 2 Valve Engine oil capaci 1.3 hires at disassembly and 1.09 fires of oll droning Lubrication system Forced pressure and wal sump Engine [Oil pumo type rachoid Gil flration Centrifugal ype Ar fitration Viscous paper ype Cylinder compression pressure 12.0::2.0 kaflem" Open ]o" TOC) Invoke valve Close 37 (ABDC) Exhaust valve ‘Open __}36" (280¢) Close [0° OC) 1-5 GENERAL INFORMATION SPECIFICATIONS [— GENERAL TEM ‘SPECIFICATIONS: Intake [0.12 mm Valve clearance how | Tame Idle speed 1400= 100 rem Clutch system Push iype dug cuich system, ransmission S-speed constant mesh Primary reduction 3136 (69/22) ¥ 3.07 (40/13) A a 1.789 (34719) Drive train | oor roto 3 7.304 (80/23) e 1.1 (22/20) 5 0.958 (23/24) Final educion 3.07 (40/13) Gearshifipatera Toe shift 1-N-2-3-4-5 Ignition system Fuel injection system ‘Alternator 120W @ 5000 rpm (single phase full DC syster) Battery capacity MF Battery-12V-4 AR/ETZS Electrical [Spark plug NGK-CPR 8 EA, BOSCH URSDC system | Sporkplug gap 0.8.0.9 mam Starter magnetic switch [20A (Circuit fuse) & 20A [Spare fuse) Fuse 15A,10A, 108 & 104 Main fuse) Fuse box Headlamp Hl Position lamp iai/stop lamp Tur signal lamp LED Meter illumination Module illuminated (CD Neutral indicator LED tagnes! , [Tumsignatindicotor RANA) LED High beam indicator LED ABSindicolor LED Service reminder indicator Module lluminated CD. Programmed Flmallunction indicator lame [Mil] [LED Side stand indicator LED licence platelame TSW “MF stands for Maintenance Free 1-6 GENERAL INFORMATION SERVICE LIMITS [MAINTENANCE Throtle gp free play 26 mm Spark plug NGK-CPR 6 EA 9, BOSCH URSDC Spork plug gap 0.80.9 mm Vals clearance Inioke 0.12 mm {In cold condition Exhaust 0.13 mm ' At draining 7.08 lies Engine oil capacity |At disassembly 1.3 litres: Brand : Hero 4T Plus Grade : SAE 10W 30 Sl Grade JASO MA2) Manufactured by Recommended engine ci 1. Tide Water Oil Co. (India) Ud 2. Savite Oil Technologies Limited. 3. Bharat Petroleum Corporation Limited Engine idle speed 14002100 rpm Gylinder compression 12.0220 kaffem® Drive chain slack 20-25 mm Recommended broke fluid DoT 3 or DoT 4 lurch lever free ploy 10-20 mm + Front | 100/80 17 52 P [Tubeless tye) _ Rear___| 130/70 R17 62 P [Radial tubeless tyre) Front [1.75 kai/em (25 psi Rider only Rear | 1.96 katfem™ (28 psi) Cold tyre pressure Front, 1.75 kaf/em’ (25 psi) Rider &Pillion [Rear | 2.10 kaf/em"(30 psi Front__[0.8 mm Recommended minimum tyre tread depth aes " den Rear 1.0mm LUBRICATION SYSTEM: ITEM ‘STANDARD SERVICE LIMIT [AT draining 1.09 res : Engine olleapaciy Tas disassembly 3 lives - Brand: Hero 4T Plus JGrode: SAE 10W 30 SL Grade (JASO MA) Manufactured by: Recommended engine oi 1, Tide Water Ol Co. (Indio) Limited ' 2, Sovita Oil Technologies Limited. 3,_Bharat Petroleum Corporation Limited. Outer retor-body clearance _[0.15-0.2) mm [0.26 mm Oil pump Rotor tip clearance 0.15 mm [0.20 mm Pump end clearance [0.03-0.09 mm [0.15 mm 1-7 GENERAL INFORMATION [— FUEL INJECTION SYSTEM ITEM ‘SPECIFICATIONS Fuel injedior resistance 450 EOT sensor votage V=01V EOT sensor resistence 2.645=5% KO @ 20C Fuel pressure 300-10 kPa Injector voltage Battery voltage ‘Onygen sensor resiston 300 KO @ element tip temp > 300" C Viich =0.7V and Viean <0.12V@ Onrgen sensor voltage element tip temp >300° C ACY resistance 477-583. ot 25°C BAS iil angle 5827 [ENGINE REMOVAL/INSTALLATION ITEM. SPECIFICATIONS - ' [At droning [1.09 lives Engine ol cop! Ar disassembly [1.3 lives CYLINDER HEAD/VALVES ITEM STANDARD SERVICE LIMIT Cylinder compression 12.02.0 kgf/em : Vobe a Intake 012mm : ole clearence Exhaust Timm - Intake 590-38.790mm 33.55 mm Camshaft cam lobe height . Bihaust 33.458-33.658 mm 33.42 mm Cylinder head warpage - 0.1 mm 1D. 10.000-10.015 mm 10.08 mm Rocker arm [Shaft O.D 9.972-9.981 mm 9.95. mm Rocker arm-to-sholt clearance O11 mm Infoke 4.975-4.990 mm 4.945 mm Stem ©.0 Exhaust 4.955-4.970 mm 4.925 mm Infoke 5.000-5.012 mm 5.03 mm Guide LD Valve Exhaust §.000-5.012 mm 5.03 mm Intake 0.010-0.037 mm 0.08 mm Stom-to-guide clearance Exhaust 0.030- 0057 0.10 mm Spring free lenaih Inner 37.78 mm [36.78 mm Valve seat widih Lamm Sm Specified height of inlet vahe guide 18.020.) mm Specified height of exhoust valve guide 14.25=0.1 mm 1-8 GENERAL INFORMATION [- CYLINDER/PISTON TEM STANDARD SERVICE LIMIT 1D 57,300.57. 310mm _ [57.38 mm Crlinder Taper Olen Warpoge 5 ‘O.1mm Pision OD 57.280.57.295 mm _ [57.21 mm Piston pin hole 1D 4,002-14,008 mm _ [14,04 mm Piston pin O.D 3.994.14,000 mm _ [13.96 mm Pision-to-pisvon pin clearance 0.002.0.014 mm [0.07 mm Connecting rod small end LD 4.010-14.028 mm _ [14.06 mm Grlindero-piston clearance 0.005-0.030 mm [0.10 mm . Connecing rod-te-pision clearance 0.010-0.034 mm [0.10 mm Peon Piston ring-to- Top 0.03-0.060 mm 0.10 mm groove clearance [Second 0.030.060 mam 0.10 mm ic 0.10-0.25 mm 0.60 mm Psion ring end gop [Second 0.25.0.40 mm 0.70 mm Gil de rail 0.10-0.40 mm 0.70 rm CLUTCH/GEARSHIFT LINKAGE/PRIMARY GEAR DRIVE ITEM STANDARD SERVICE LIMIT Lever free play 10-20 mm - Spring free lengih 40.50 mim 39.6 mm Dise-A (0=2) green 2.92-3.08 mm 262 mm Dise thickness Dise-B (a=3) 2.92-3.08 mm 2.62 mm Clutch Plate worpage - 0.2 mm Clutch outer guide LO 16.991-17.009 mm [17.05 mm [Clutch outer guide O.D 22.959-22.980 mm _ [22.93 mm [Clutch outer LD 23,000.23.021 mm _ | 23.08 mm ck soner [ion 16.076-16.034 mm —_|16.09 mm Spindle O.0 5.966.15.984mm [15.95 mm 1-9 GENERAL INFORMATION [-ALTERNATOR/STARTER CLUTCH ITEM STANDARD | _ SERVICE LIMIT Gear reduction Shak OD [8.972-8.987 mm [8.92 mm Sjone dive gen 1D 29,000-29.021 mm | 29.06 mm lop 45.660-45.673 mm] 45.64 mm [-CRANKCASE/CRANKSHAFT/TRANSMISSION TEM STANDARD | _ SERVICE LIMIT 1D 10,000-10.018 mm] 10.05 mm Shi fork Claw thickness 4.93-6.00 mm [4.53 mm Sholt OD 9.986.9.995 mm [9.99 mm teh 23,959-23.980 mmm| 23.94 mm loo shit um Right 20.959-20.980 em) 20.94 mm Joomal io tel 24,000-24.083 mm) 24.05 mm Right 21,000-21.021 mmm] 21.04 mm M4, MS | 20.000-20.021 mn] 20.06 mm - co 23.025-23.046 mm] 23.09 mm Geer @ 23.020-23.041 mm| 23.08 mm a 20,500-20.521 mmm) 20.56 mm M4, MS_[19.959-19.980 mm] 19.91 mm Bushing ©.D a 20459-20480 mmn|20.41 mm €2,C3 | 22.984-23.005 mm| 22.98 mm sushng 1D M4, Cl___|17.000-17.018 mm| 17.04 mm €2,€3 | 20.020-20.041 mmm] 20.07 mm MS,C1, C3 [0:020-0,062 mm [0.10 mm Tonsmission JGearto bushing clearance [G2 0.015-0.057 ram [0.10 mm Ma 0.020-0.062 ram 0.11 mm IMA, C1 |16,966-16.984 mm] 16.98 mm Moinshah/Counterhatto.0 [arC2 19.978-19.989 mm] 19.94 mim 3 19.979-20.000 mm|19.94 mm M2,M3__[0.016-0.052 mm [0.09 mm Gear 1o shat clearance “ SE ee M4, C1 [0.016-0.052 mm | 0.09 mm Bushing-to-shft clearance [C2 0,020-0.057 mm [0.10 mm c 0,020-0.062 mm [0.10 mm Ronout - 0.05 mam Crankshaft Big end side clearance 0.10-0.85 mm [0.60 mm Big end radial clearance 0-0,008 mm [0.05 mm 1-10 GENERAL INFORMATION ; Piston 1D 20,000.20.021 | 20.08 Kick stoner Spindle OD 19-959-19-980 | 19.94 [— FRONT WHEEL/SUSPENSION/STEERING ITEM STANDARD SERVICE LIMIT Minimum tye read depth 0.8mm Cold ye prossure Rider only 75 kal/em (25 psi Rider & Pillon 75 kal/em* (25 psi) Front axle runout 2mm Front wheel rim runout Reset SA zon Batol Oman 2mm Wheel balance weight max60.9m E Fork spring ree lengih 4B.b mm E Forkiluid level 154mm - Fork lid copacity 305 ce - [REAR WHEEL/BRAKE/SUSPENSION ITEM STANDARD SERVICE LIMIT Minimum iyre tread depth Om Rider onk 76 kal/em'(28 psi : Cold tyre pressure y ae notion eee Rider &Pillion 2.10 kat/em (30 psi z Reor axle runout 0.2 mm : Rear wheel rim runout Rediol SA mm 2rm [axial 0.4 mm 2mm [Wheel balance weigh max.609m Rear brake lever ee play 10-15mm - Reor brake drum LD 130mm - Rear brake lining thickness 4mm - [ANTI-LOCK BRAKING SYSTEM iem SPECIFICATIONS. Wheel speed sensor resistance 50 022% - 115 Q=2% Wheel speed sensor air gop 0.9 mm Maximum (Operating temperature 10°C 10 80°C Operating voltage 9.8 10 16.1V) ‘ABS unit inclination angle 5°25" Inclined 1-11 GENERAL INFORMATION (TUBELESS TYRES ITEM STANDARD ‘SERVICE LIMIT Cold tyre pressure Rider & Pillion 75 kgf/cm’ (25 psi) Rear Rider only 96 kgf/cm’ (28 psi) Rider & Pillion 2.1 kgf/cm’ (30 psi) Wheel rim runout Axial 0.4 mm 2.0 mm Rear Radial 0.4 mm. 2.0 mm. -vonic ak ron [Specified brake fluid DoT3-DoT4 Brake caliper piston O.D_ 26mm [Specified brake fluid DoT-3 or DoT-4 |Capacity *MF Battery: 12-4 Ah/ETZ5- “MF stands for Maintenance Free 1-12 GENERAL INFORMATION TIGNITION SYSTEM ITEM ‘SPECIFICATIONS Standard INGK-CPR BEA, BOSCH URSDC Spark plug Spork plug gop [0.8-0.9 mm Peak voltage CK? sensor T.5.V (Minimum) @ 300 rpm (gop 1.1 mm) Primary coil resistance @ 20°C/68F [2.30 10% lgnition coil Secondary coll resistance . (without noise suppressor cap) @ 20°C/68 T1ka=20% CKP sensor resistance 50-2000 ELECTRIC STARTER: ITEM STANDARD SERVICE LIMIT Starter motor brush length 7.0 mm 3.5 mm [- LAMPS/METERS/SWITCHES ITEM ‘SPECIFICATIONS Headlame (High/Low) LED Position lamp LED Tail/Sloplamp LED Turn signal lamp LED Meier illumination [Module Wuminated CD Bulbs Neviralindicator LED urn signalindicator H/H) LED High beam indicator LED ‘ABSindicator LED Service reminder indicator Module Wuminated CD Programmed Fl malfunction indicator amp [MI]|LED Side stand indicator LED Licence plate lamp T2VSW Starter magnetic switch|20A (Circuit fuse) and 20/ Fuse T5A, TOA, 1A, & 10A, (Main fuse) Fuse box TSA, & JOA, (Spore fuse 1-13 GENERAL INFORMATION [~ ENGINE TORQUE VALUES. TORQUE PR nO. iTeM sun a vee Nem | kgm |VALUES) REMARICS 1 Beno held plete Méx1.0 Flange bol jo~14 | 10-14 12 coring push alate IMéx1.0, SH flange bok 0.8~1,2 10 3 | Oil drain bolt (Left case) [M12x1.5 2.5~-3.5 30 IMI4x1.6 Cap, 14mm 08-12 | 10 4 [eth cover [M32x1.5 Cop, 32mm 0~2.0 15 | Apply grease 5 [com sat poe IMax1.25 Special nut 31-35 | 32 [Apply engine oil [M5x0.8, Flange bolt 0.45~0.6 5 6 [Head cover IMéx1.0, Special bolt 08-12 | 10 7 | Cam sprocket [M5x0.8, Flange knock bolt 711 07~1 9 & | Tappet adjusting nul hMéx0.75 Not 2-16 | 12-16 | 14 _ [Apply engine o 9 | Tensioner lifter adjust hole |Méx1.0, Screw pon 3.4~5.0 | 0.35~0.5 4 10 [Oilpume [iepping screw 4x8 25-39 | 025-04 | 3 11 [Oil filter rotor IM14x1.0, Lock nut 59~69 6.0~7.0 64 | Apply engine oil 12 |Cap, ol fier rotor [M5x0.8, Ovel screw a5 [03-05 | 4 13. [Clutch assembly [M1 4x1.0, Special flange nut | 69~78 7.0~8.0 ia Apply engine oil IMéx1.0, Flange bolt joni4 | 10-14 | 12 14 |Drive sprocket [Méx1.0, Special hex bolt 10-14 10-14 12 15 _|Shift drum stopper plate [Méx1.0, bolt hex 10~14 1.0-1.4 12 TB#1322N Equiv 16 | Shift drum stopper IMéx1.0, Special fange bot | 10—14 | 1.0-14 | 12 | T8#122N Equiv 17 [Engine oil temp sensor [M10x1.25, Special flange bolt ~16 31.6 14 TB#1322N Equiv 18 | Oxygen sensor [\i2x1.25, Special flange boli] 20-30 | 2.03.0 25 _|1B#1322N Equiv 19. [Speed sensor [Mé.0x1.0 e-12 | 08-12 | 1.0 |T8#1322N Equiv 20 | Starting clutch outer [Méx1.0, Special socket bolt 4~18 4-18 16 | TB#I322N Equiv 21_[ACG fiwheal [Mia O,lange nut 69-78 | 70-80 | 74 |Apelyengine ol 22 [Pulser IM5x0.8, socket bolt 44~6.0 | 045-06 5 TB#1322N Equiv 23 _|ACG cord clamper [Méx1.0, socket bolt 10~14 1.0~1.4 12 TB#1322N Equiv 24 [Spark plug Mio«1.0 Te [18 [16 25 [Balancer shat Not flange M12 49-59 | 5-6 56 26 |Right/Left cronckcase IMBx1.25, Bolt cylinder stud | 7~15 07-15 27 [Insulator band IM5x0.8, Screw pan oa-i2 | oa-o12 | 1 28 Pin shift return spring IM8x1.25 25~34 2.5~3.4 30 | TR#1322N Equiv NoTE 1, Factor for conversion of torque velve SI unit -m) from customary unit {kgf-m) shall be 9.8 2. Center Valves in PR value. (Those shall be entered in shop/service manual) in this table. 1-14 GENERAL INFORMATION ;- FRAME TORQUE VALUES SR. THREAD TORQUE FR No. rem sweeties [Thm | kaw [VALUES] REMARKS [prom 1. [Steering Top bridge bol M10x1.25, 22~25 2.0~2.5 22 BF 2 [Whe Front disc bolt M 8x1.25 39-44 4.0~4.5 A2 (82361) Driven sprocket nut M 10x1.25 59~69 6.0~7.0 64 PT nut Front speed sensor disc bolt M 6x1.0. 8~10 0.8~1.0 9 Bolt flange Front engine hanger M8x1.25, 24~29 2.4~3.0 26 [Upper engine hanger M 8x1.25, 24—29 2.43.0 26 [Front caliper (Front fork fitting use) | M 8x1.25 27: 2.8-3.4 30 BF (TB2361) [Front master cylinder cap M 4x0.7, 1.0~2.0 15 Screw ich HATO e993 33 F Front caliper bleeder M10x1 12-16 14 [Rear caliper nut flange M8x1.25, 19.6~24.5 | 2.0~2.5 22 Apply asec AS10-AQ] Rear caliper hanger pin M10x1.0 14.7~19.6 | 1.5~2.0 7 Rear master cylinder connector M 4x0.7, 1.0~2.0 0.1~0.2 1s Apply loctite 569. |Clamper front brake M 6x10 8~10 0.8~1.0 9 BF 1-15 GENERAL INFORMATION -- FRAME TORQUE VALUES- 4 TRAD TORGUE PR se vem ate | K tatm VALUES] REMARKS = [Suenn Rear cushion upper M 10x1.25 45-55, 50 BF Rae xen weer M125 25255 [50 ar 7 [Swingarm Swingarm pivot nut M 14x15 55~65, 5.5~6.5, 60 7” [nde bor Tet hd Tar A ie nd ver 16-0 4969 | 05-07 [39 Handle ole par bot [x0 To=14 [19-14] 2 8 [Fuel tank Plate setting M 6x1.0 10-14 1.0~1.4 12 Terk mn a HTZ5 Te=25 | 18-25 | 21S Purge ve novning bot [Méxi5 B10 te=10-[ 9 Sty pg vale owning Fa [6-0 a2 oe? | 0 9 | Step Sep ASH WIS ce Fag bol HIDE Te=2s| aaa Left main step assembly M 8x1.25, 18~25 1.8~2.5 21 Right main step assembly M 8x1.25, 18~25 1.8~2.5 21 stp pllon oven be 5 Te=25 [1835 [a Tigi sep plone [ M8. 25 Te=25[ 1875 [ai Sear dange sa ba eer yee oi [2 (0 | Side stand Pot bot won 25 a | a0 | Tk HT 25 way ao-30 | eo 7 [eats Throttle cable (Grip side) M 10x1.25 1-2 0.1-0.2 5 12 | Switch assy. comb. & lock mounting | M 8x1.25. 18~25 1.8~2.5 21 Apply loctite 3 | Body cover Fen fende Rona aTS Tara [Sara ing mourng duckie [W508 aa-5 | oae0s [a2] Scenpon Fron coe wpe W508 34-5 [oaesos [aa [Sem Tank cover front M 6x1.0 7-1 0.7~1 9 Tank cove ear 1508 aa [aes | aa | Samm Side er SID 7ai[ aya [9 [Seen Rear cowl M 5x0.8 3.4~5 0.34~0.5 42 wo rea | ove-ta D9 Rear fender M 4x1.41) 1.7~2.5 | 0.17~0.25 2) Screw tapping ‘Stay meter sub assy. M 6x10 98-14 1.0-1.4 12 1-16 GENERAL INFORMATION ;— FRAME TORQUE VALUES- TORQUE 7m sr. THREAD rem lvaLUes| REManks no, sieeve: [nom | ktm [VALUE = Soy ing hoy nan tee ee | Broke nner prel suppor [Méx.o ge-14 | 10-14 | 2 Sioy rn! somber plate Mér.0 ve-1¢ | lone | 2 Chain cove Mén.0 ea [9812 [10 Bate eate Mox.0 e-12 | 8-12 [10 a [ect Hook el coh Men ve Dios [2 3 [Ror ai Grip Right/Left rear sub assy. M 8x1.25, 24~29 2.4~3.0 27 [Keck moving bo Tae 25 eas | 828 [21 7 |Oher lea aed weer25 em [eas | A Sores guard Be 25 eas [ 18258 2 73 [fer Tiler asa meng [WBE wa aaa [2S 17 Ar cleans Cover Air/C case M 5x0.8. 1.3=1.7_ | 0.13-0.17 Ls BO. soso Ted 25 30-30 | 2.080 [25 1 [ Man Ford Ton WTGTZS S18 | 15-18 | 165 Specie eng rafod proce a Tem Side sand Moin ond When ighntng ck oat Pivot screw & Lock nut Bolt shall be fixed by tool Item: Handle lever When tightening lock nut pivot Pivot screw & Lock nut Bolt shall be fixed by fool Tem deone conrecing Wb aE a a 7 A. Width at fastening of band of air cleaner connecting shall be 9-0.5 mm / B. Wh fastening of bono instr shall be 1031 mm NOTE 1. Factor for conversion of torque value SI unit (N-m) from customary unit {kgf-m) shall be 9.81 Center values in PR valves (those shall be entered in shop/service manual). 1-17 GENERAL INFORMATION GENERAL TORQUE VALUES STANDARD FASTENER TYPE TORQUE (N-m) TORQUE (kgf-m) Smmbolt and nut 44-60 0.450. 6mm bolt and nut {include SH flange bolt) 8~12 08-12 8mmbolt and nut 18~25 18-25 10mm bolt and nut 29-39 3.0-4.0 12mm bolt and nut 49-~59 5.0~6.0 4mm screw 75~2.5 0.17~0,25 [5 mm screw 34-5 0.35~0.5 6mm screw: 7-11 07-11 6mm lange bok {including NS 98-14 1.0~1.4 8 mm flange bolt and nut 24~29 2.4~3.0 10mm flange bolt and nut 34-44 35-45 NOTE * Torque specifications listed above and on the following pages ore for imporiont fasteners. 1+ Others should be tightened fo stondord torque values listed above, ‘SPECIAL TIGHTENING PROCEDURE R/L CRANKCASE ‘CYLINDER HEAD EMBED TO| 125.441 INCOMPLETE THREAD 1-18 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE Pt BLOCK NAME METHOD PuR-| OR PARTS NAME APPLIED AREA |MATERIAL| nD AMOUNT —_[POSE| REMARKS Three-bond Bs, ft crankcose Moting surface #1218 or | Spreoding 2 . #12076 s Bearing push plate 7 SH, 6x18 (let pee | crankcase) Threaded portion #13242 or | Precoating orspreading| 3. [Costnawidh Beoring hold plate BF #2415 oF "om tip 4x16 (Right crankcase) Loctte#200 rah ohip Wile sce Engine al Three-bond ACG grommet Sealing surface FUSS | Spreading 2 #12076 Cap 32mm Threaded portion 5 Ghlinder loner surface of ender deve | ine oi 1 MB special nut (einder [Threaded portion, Seating Spreading or dripping stud) sofa Needle bearing of connecing Smnng item | Coane rod big end Engine ol rankshaft component Tine surface of connecing | with MoS, 1 rod small end Spreoding oF dipping Piston ia hoe ng groove, siding area | Engine ol 1 Engine oll Piston pin Outer surface 1 with MeSs_| oi bath or spreading Fison Ang Whole sulace Engine ol 7 ACG & Left crankshatt_[Tapered suroce Degreasing 5 Né14 Flange not [Threaded potion seating . ‘ EFlwheel surface Engine oil | Oil bath 4 Volve(ivake/Exhavs) [Outer surace stem, sem end | Engine it | Sereading ordrpning | 1 Camshaft component _|Whele com surface wih MoS: [Spreading or dripping [1 Cam chain Whole surface Oil bath or spreading [1 Rocker orm sho Whole surface Oil bath or spreading | 1 Taner surace of boss, rller Rocker erm Inner sy _ [Serceanararerine | 1 Engine oil Toppel edjaing nut | paded potion seating Oi bah 3 Gil pump assembly Rotor Pouring rom oiler 7 M14 Lock nat pain sealing Oi ban 7 (Oil iter rotor) 1-19 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE BLOCK NAME METHOD PUR CnLOCK NAME | APPLIED AREA mareriaL | ,yMMETHOD [PUR] REMARKS Oil through Sliding surlace Engine oil | Spreading Clutch outer quide | 23 outer surface Engine oT J Oil bath or spreading Chaich disk Whole surface Engine off | Oil bath Chach outer component | Sliding surtace Engine ol Spreoding Chich iter rod Whole surlace Engine oil N14 Flange nut readed portion Oil bath (Clutch center secting surface Engine oll 4 Ned, 5 gear Inner surface Spreading M4, 5 gear inner bush [Whole surface snoine ot [Lib orsereadina C2. geor Tmer surface Engineol TS eoding C-1,2,3 gear inner bush [Whole surlace Oil bath or spreading i-3, CA, C5 gear | Shif fork groove surface Gear Primary mission, [x Spreading Sear foot flank Engine oil Shift fork shaft Whole surlace Oil bath or spreading Shi eum joural | , Engine OF | ing oral Change spindle journal ° Preoeling ov peng ts Shit drum stopper plate #1322,41322N 3 |cooting width 650 Per PIN | shreaded portion or #1324Z or | Precoating or spreading Coating width 65: #2415 or Loctite mmm from tip Shif drum stopper #200 a Starter deven gear Starter driven 9} Inner surface Spreading Kick star pinion Engine oil wth MoS, Kickidle avorinner whole surace bush Oil bath or spreading Starter eitch Rolling surface Engine Ol Socket bol 6x1 6 ae Coating with ecko Threaded portion #1322N or "recoating of spreadin, cent (Storer clutch outer) | pos 13047 or #2415 | Tecoaina oF sPreading | 316 51 mm from tp or Loctle #200 Sater GION The race Ercne Ol | Spreading Socket bot 6x16 18#1322, 3 (Pulser) che #1322Nor_| scsi or son Coating width hreaded portion 1a Nr, | Precoating or spreading Senin with Socket bok x16 or Loctile #200 y (ACG cord clamper) 1-20 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE BLOCK NAME ‘METHOD PUR. onparis Name | APPLIED AREA MATERIAL | ann AMOUNT pose] REMARKS Ball/Needle bearing _ [Rolling surface Pouring from oiler 1 Fraine oll [Oibath 7 enone al yoo | MC 4-stroke ss low 30 SL Engine el Inside of crank case | ggsaline engine oi| 1200ce (Upper level ASO MA} (for service onl) 900ce (Lower level) 1000ce (Exchange) Bearing, Roller Engine oil 35.7215 Ball surface ran Spreading or dripping | 1 NOTE T 2. Engine oil for spreading shall be 4 stroke vehicle gasoline en. oil which does not contain molybdenite Molybdenum disulfide paste content in Molyadenum disulfide oll shall be 50% in volume percent PURPOSE 1. Lubrication 2. Seal 3. Lock 5. Others |4. Apply for torque stabilizing 1-21 GENERAL INFORMATION LUBRICATION & SEAL POINTS FRAME lsk.] BLOCK NAME METHOD [PUR- INO| OF PARTS NAME | APPLIED AREA | MATERIAL OF AMOUNT pose} REMARKS 1 [Steering Steering cone race Shell akcania EF2 oF Torna bl cace 7 Pllna contac surface |eseohe Ep? filling 3~$ gm 1 : {Kyodo yushi co.) Steering dust seal [lip surface Jor equivalent Spreading 1 2 [Suspension Front fork inside Oitiyeelé ot [Iniect 5 Front fork oil seal Lip surface eect 8-22 Spreading 1 Swingarm booing insde HES © 2012-81-2 [iting 1 Swingarm pivot Lip surk Spread Sengarn ip surface HES D 2012.3-1-2 | Spreading 1 Swingarm pivot nut [Threaded portion [HES D 2012-3-1-2 [Spreading 1 gm min | 4 3 [Broke Front brake coliper pa Sliding portion | Brake grease specall Spreading 0.4 gm min | 1 No areas on lining surface Front brake caliper liding portion rake grease special Spreading 0.4 gm min allowed eA sliding por Brake grease special Spreading 0.4 a 1 ont brake piston |Sliding portion by oil readin Front brake pist Sliding por Brel | Spreading 1 Front brake caliper ASEC AS10 AQ or octena Threaded postion |e ny Spreading 3 Front brake lever pivot [Sliding portion [Brake grease special|Spreading 0.1 gm min | 1 Fron’ brake master [inner surface ond [Assembly oll veodin ojlinder piston sliding portion CCI-No20 _[Sereadina | Front brake master | ake grease spectll Spreading 0.1 gm min cide mcahvad” [Sliding potion | Brke grease special Spreading 0.1 gm min | 1 Front brake master [Inside of master 7 wc lo unper level To up level afer eylinder eylindor cue POTS or DOT 4 | Inject to veper level comple’ air bleeding Rear brake caliper |g Spreading cee Sliding portion [Brake grease secil 9 Din 1 Ne rn on ining surface Rear brake cali 7 Spreading ee: retena Slicing portion |Broke grease special 8a rin 1 | ollowed fear brake piston liding portion Assembly oil readin Rear brake pis Sliding por eso (Sereadina 1 Rear brake caliper aroun Silicon grease | Spreadin Sooper rng All round 9 Spreading 1 1-22 GENERAL INFORMATION LUBRICATION & SEAL POINTS FRAME BR] BLOCK NAME METHOD PUR BR] BLOCK NAME | appuzp area | materia, | METHOD [PUR] remarks Rear bake caliper |, sec 03 S010 or Reor broke Ireaded porion [fee 0% 59 Spreading 3 Rear broke master nner surface and | Assembly oil Spreading cylinder piston [sliding area CCI-No20 8 Rear broke ma eer broke ose pling oreo Broke grease specia| Spreading 0.1 gm each brake master Inside of master To up level ater Ssor broke master [inside of mos DoT 3 orDoT 4 | Injectto upperlevel | 5 | complete oi ” Y P bleeding 2 [Wheel Front wheel oil seal Lip surface HES D 2012-2. Spreading Driven lange dust seal Rear wheel hob O-ring All around HES D 2012-2.1-2 [Spreading Rear wheel oil seal Lip surface HES D 2012-2-1-2 | Spreadit 1 Front and rear tyre Bead seat « Negetstle 02 | Spreading 5 5 [Speed sensor assy Dust seal ip Shell avania grease [Spreading 7 Magnet nner dia Shall ovonia grease | Spreading 1 6 [Hondle Cluich lever pivot boll | Sliding portion HES D 2012-2-1-2 |Spreading 1 Grip kfthandle [Matching suface PAO emesirel | soreading 3 | 80% min of contac Grip com rottle |Contact area of reading Grip comp. Throttle eee oe ond [MESO 2012-2-1-2 |Spy a 1 7 [Change Change pedal piv ioe — Sliding portion HES D 2012-2-1-2 |Spreading 8 [Air cleaner [adhesive sal no Air cleaner case, [Case connecting area | #949 leemedine) |. caging Conn, Tube, duct [OP SEMMECTMBAES] or equivalent | PEOENG ? eee 9 | Control cable Silicon greore Inside of boot esis!) or Filling 2 Throtle cable ae Inside of casing molybdenum alloy |Filling 1 oil MAO or equivalent 1-23 GENERAL INFORMATION LUBRICATION & SEAL POINTS FRAME JSR. | BLOCK NAME INO.| OF PARTS NAME METHOD _|PUR-| ‘APPLIED AREA, MATERIAL OF AMOUNT |Pose| REMARKS Inside of boot 251} or Filling 2 [Clutch cable Savivalent TSG 3203 or Inside of casing | mohodenum oloy | Filling oil M-AO or equivalent TSG 3203 or Seat lock cable Inside of casing molybdenum alloy | Filling oil MAO or equivalent 10 [Others Side stond pivot Sliding portion HES D 2012-2-1-2 | Spreading [Main stand pivot [Sliding portion HES D 2012-2-1-2 | Spreading Threebond Comb, & lock ‘Theeaded portion _|T8-1342n or locite | Spreading 3 switch bolt 1262 oF equivalent Seat lock Sliding portion HES D 2012.2-1-2 | Spreading M/Step Sliding portion HES D 2012.2.1.2 [Spreading P/Ste Sliding portion HES 0 2012-2-1-2 | Spreading P/Step (SPS) Sliding portion HES D 2012.2.1-2 [Filling 11 [Brake Rear broke pedal —_|SIiding portion HES 0 2012-2-1-2 |Spreoding PURPOSE 1. Lubrication 2. Seal 3. Lock 14. Apply for torque stabi 5. Others 1-24 GENERAL INFORMATION SPECIAL TOOLS sls, Descn [APPLICATION PART NUMBER 1_| Flywheel puller To remove the flywheel from crankshaft. O7OHHKTCOO4 Z| Socket wench Te remove lok ut om dich assy and rotor Hr] OTOHH 98002 3° | Universal holder To hold the flywheel while removing flywheel nut. |070HH198003 4 | Choch conte holder To held he ceive cuich while removing the lock nut: [OTOHT9BO04 5 | Vale spring compressor Te compress ie valve sping and remove he | o7ot41 98005 ©_[Tonpet odiuser wih socket, Pram To odst valve clearance O7OAIFBOOS 7 [Ball ace diver Te remove and intl ball aces fom head pipe. [O7OMHIVBOO7 | Bator cone race punch [Dvner Sem bean] To Insert botiom cone race in steering slem O7OHHI98008 9-_| Universal bearing puller Te remove cronkshoft bearing O7ORATB007 TO | Vote guide remover Te remove valve guide Rom ofinde hood O7OHHIVEOIO TT [ Teppet cover wench Te open and tighten the tappet cover o7OnFTIFEOTI 12. | Socket, 17.5 mm Te be vsed wih prevmotc gun-cvich Tock nal, [OTOHHIV8O12 13 [Aluminum plug ‘To block vel pipe hose while removing from carburetor | O70HH198014 T4_ | Average testing bolle wih fare Ta meosure ful average O7OHHIVEOIS 15 | Plastic oil seal guide kit, 5 pcs. ‘To install stator plate oil seal. }O70HH198016 16 [GPO holder Te provide gear locking between GPD and chich ove [O7OHAI98017 17 | Front fork oil seal driver body ‘To drive in new oil seal. }O70HH198018 18 | Fron fork dismanting tol Ta ald fer ube sea while opening he boom loot 9a020 19" [ Compressor rear shock absorber Te compress sping for demonling rear shock absorber] O7OMATOBOD 20 | Oil pump spindle holder ‘To remove and lock the oil pump spindle. }070HH198023 21_| Swing orm pivot nul socket, VT To open and lock pivat ul O7ORATIEOD Z| Colle bearing remover, T2mm Te remove bearing from crankcase [avon 98036 23,| Piston side bose To secure piston while assembling einer O7ORAT9BOIT 7a | Race steering cone inserer Te inser ball race n seerna pipe avon 98038 25_| Socket rotor iter aut Pneumatic, 24 mn) [To be used with pneumatic gun-otor er aut, [O7OHHT 98029 26 [Ratchet spong ineerer To inser Kick shat ratchet spina O7ORAT7EOSO 27_| Driver, 40546 mim Te sect on autor ace suoce and dive own he boarng| O7OHAT9BO3T 28 [Flt 7mm To seat inte inner ace and dive oun the bearing, [070198033 29, | Cop, Mafler (100 CD series Te reset water evry during washing, [avon 98035 30 | Brake pad hanger pin remover To remove brake pad hanger pin from caliper assembly,| O70HH198036 31_| Main/side sond spring insaler Te instal main ond side stand spring O7ORATB037 32 | Socket steering stem nut, 32 mm. To remove and tightening the steering stem nut. O70HHGBG004 3S. [Font farolseol diver afochment dia, 0 mm | To drive in new ol seal [O7OAARCCOOT 24 [Tappet adjuster with socket, 10 mm [To adjust valve clearon [O7OHHKFNOOT 35 | Flywheel puller (CBZ) To remove the flywheel from crankshaft. }O70HHKFNOOZ 36 |Pever’s pier Te remove 59 na from master cylinder ond O7OHHKFNOOS 37 [Font for oleol diver aiochert dio Simm To drive in now ol sea JO7ORRKENOOA 1-25 GENERAL INFORMATION SPECIAL TOOLS ss, DESCRIPTION APPLICATION PART NUMBER 38_| Cronkcose bearing remover coled, 15mm [To remove bearing fem eronkeave O7OHHKENDOS 39 _[Crankcase bearing remover shaft To remove bearing from crankcase. ‘O7OHHKFNOOS 40_[Cronkcose bearing remover weight To remove bearing rom cronkcore O70HHKFNOOT, @1_[Handle bearing driver To hold pilot and driver outer to remove/insert bearing, [O7OHHKFNOOB: 42 [Driver outer, 42x47 To sat on over ace soc ordre on he beorng|O7OHHKFNOT 1 43 _ [Pilot driver, 12mm To seat in the inner race and drive out/in the bearing. |O7OHHKFNOT2 44 [Flor driver, 15mm To seat inthe ner ace and dive oti he boorng. [OTOHHKENOTS 45_| Pilot driver, 21mm To seat in the inner race and drive out/in the bearing. [O7OHHKFNO14 46 [Flos driver, 28mm To seat nthe inner race and dive out/in the bearing, |O70HHKENOTS 47_[Remover head, 12mm. To remove wheel bearing from wheel hub. ‘O7OHHKFNOI7 48_[Steering bearing edjusternvt socket [To adlut/remove the steering bearing ouster not [O7OHHKFNOIS: 49 [Dever 26:27 mm To sea on oer oc svfce and dive on he bearing] OTOHHKFNOZI 50_[ TPS es! connector To reset rote potion sensor O7OHHKRYOOT 51_|Flywheel puller To remove the flywheel from crankshaft. O7OHHKRYHOOT 52_[ Flywheel pula holder To hold the fywheel puller O7aHHKRYHOO? 52 |Cronkshof pit To avo Ihe damage of consha ods during | oyqyay ons 54 [Magnet holder (Clamp type) To hold magnet while removing the lock nut. ‘O7OHHKRYHOO4 55 [Oil cooler holder cover To be used for protecting oil cooler fins during water wash] O7OHHKRYHOO5: 56__[Fose pipe plier To pinch the fuel hore during fuel onk removal. _[O/OHHKRYHOOS 37 _|Pin-out box For diagnosing the Programmed-Fl electrical system] O7OHHKRYHOO7 58 [Tester (MF-battery} To test the condition of o MF-battery. O7OHHKRYHOOS 59 _[T-stem cone puller To remove T-stem bottom cone. O7OHHKSTOO’ @_[Bortom cone race diver To insoll Fstem bottom cone O7OHFKSTOO? 61, [Upper and botiom cone instar Te inl oper cn btm cone race o o7oHHKsTo0 62__[Steering bearing adjusting nut socket, 41mm | To adjust the steering bearings. O7OHHKSTOO4 €_ [Socket wrench (Rotor iter ond clutch) [To remove lock ut clutch ossrly and rotor fer. [O7OHHKTCOO! 64 [Socket clutch nut (Pneumatic, 20 mm) To be used with pneumatic gun-clutch lock nut opening| O7OHHKTCOO2 @_[Cich prose plate holder To hold lich centr while removing lock not [O7OHHKTCOO3 66 [Driver outer, 3235 To remove/install wheel bearing, [O7OHHKFNOTO &7 | Crankshof bearing [RES] pole com hserer| To nstalVremove (RHS) cankshok bearing O7OHHKTCOOS 68 _[T-Stem cone puller To remove bottom cone race from the T-stem. }O7OHHKTCOO6 @_[Socket, 19mm To open and lock pivot nv [O7OHHKTCOOT 70 |Cap, Muffler (Super splendor} To be used for proteciing oil cooler fins during water wash. |O70HHKTCOOB 71. [Counter sha oil seal vide To protec the courte shaft while separaina— To7oi4Ktco09 72_ [Fishel pole To remove the Hheel rom ronisho# 0708 HKINOO) 73 [Collet, 1mm To remove bearing from crankcase. ‘O7OHHKTNOO2 1-26 GENERAL INFORMATION SPECIAL TOOLS ate. DESCRIPTION APPLICATION PART NUMBER 74_[Cronkshaft bearing (LHS) puller [fo remove the bearing from crankshaft O7OHHKINOOS 75. [Boviom cone race driver a steering head pipe 76_[Pilot, 20mm [fo seat in the inner race and dive oui/n the beoring. [O7OHHKTNOOS 77_[Cronkshati bearing (WAS) inserter Fo install crankshaft (LHS) bearing O7OHHKINOO? 78 [Counter shat ol sea! aude rte he outer shat wh serv ovancnoos 79 [Rear engine foundation bush remover, 6:20 [To remave/install the rear engine foundation bush. [O7OHHKTPOT {80 _[Front engine foundation bush remover, 10:27 [To remove/insiall he front engine foundation bush. [O7OHHKTPO2 81_[Drive shat installer extension fo install the drive shaft info the left crankcase. | O/OHHKTPOS 82 _[Dive shal bearing remover with sleeve __ [To remove the drive shall bearing O7OHHKTPOA 83_[Drive face holder jo hold the drive face for removel/insallation. | O7OHHKTPOS 84_ [Driven face nut socket Fie remove/install driven face nul O7OHAKTPOS 85_[Centrfugal clutch spring remover jo remove/instll the centrifugal dutch soring O7OHAKTPOB 86 [Driven face bearing remover & installer [To remove/insiall he driven face bearing O7OHHKTPO? 87_[Fiywheel puller i remove Fhyheel. O7OHHKTPIO 88 _ [Flywheel holder io hold the fhweel for emovalinstallaion of wheel, [OTOHMITPTT 89 _ [Steering bearing adjuster nut socket, 45.3rm [To adiust/remove/install the bearing edjusiment nut [O7OHHKTPT2 970 __[Upper cone race remover Fie remove the upper cone race. O7OHHKTPIS 91_ [Bottom cone race remover head [io remove the botiom bal race from the steering head. [O/OHHKIP14 92_[Botiom cone race remover shaft [ie remove the boliom cone race O7OHAKTPIS 93_[Botiom cone race remover weight Fio remove the bottom cone race O7OHHKTPTS 74_[Upper & bottom cone installer Fie install upper and boltom cone race O7OHHKIPIT 95 __ [Clutch lever spring pin remover/installer [fo install and remove clutch lever spring pin IRVCLOSTSAABAOT 96 [Testo cone insioller To install the Testom cone race. [O7OHHKTPIS: ; “ovactor jo compress soring for dismantling front/rear 97 | Shock absorber ext econ oe O7OHHKTPI9 98 [Washing kit (Pleasure) jo restrict water entry during washing [O7OHHKTP2O 99_[Cap, Muffler (Glamour) To restrict water enity during washing. O7OHHKTROOT 100 [DLC shart connector jo read and erase the date from ECU. [O7OHHKTRFOO! 107 [Fuel pressure gauge To check the fuel pressure in fuel delivery system. [O7OHHKTRFOOS 102 [Moliimeter probe fo check he wiring in Programmed-Fl connectors. _[O7OHHKTRFOO 103 [Fuel pressure gauge adapior [To check the fuel pressure in fuel delivery system. [O7OHHKTRFOOS 104 [Remover head, 15mm fo remove wheel bearing from wheel hub, [O7OHHKVNOOT 105 [Swingarm bearing remover/installer To remove and install the swingarm bearing O7OHHKVNOOS 106 [TPS test connector To reset throtlle postion sensor [O7OHHKVNOO4 107 [Fsiem cone remover io remove stem botiom cone O7OHHKZI001 108 | Steering race remover {io remove upper/botiom steering race. lo7oHtkz1002 1-27 GENERAL INFORMATION SPECIAL TOOLS sh DESCRIPTION APPLICATION PART NUMBER 107 [Sieorng rece sialon To insole botion upper sleorng races O7ORAKZIOGS 10 [Steering odjster nut socket To remove/adivt the steering odivstng nut. O7OHHKZs004 111 [Swingarm bearing remover To remove the swingarm bearing. O7OHHKZJ005. 112 [Swingorm beoring instoller To Istll he swingarm bering O7HHKZI006 113 [Meno-shock bearing remover & insoler [To remove/nsl he reor mono shock needle bean] O7OHHKZIOO7 114 [Wheel bearing remover head, 17mm [To remove wheel bearing from wheel hub O70HHKZ008 115: [ Wheel bearing remover shot Te remove the wheel bearing O7OHHKZI009 116 [TPS test horess To reset thre postion sensor O7OHHKZIO10 117 JSwingorm stond eee ornate ne ground end O70HHKZI011 118 [Frame stand ‘To support the vehicle while doing major repairs. _ | O7OHHKZJO12 19 [Drive shot insiller eension To install dive shat info the crankcose O7OHHKZNOOI 120 | Driven face spring compressor To compress the deven face sping for o70HHKZNO02 721 [Cole 20mm Te remove deven face needle bearing O7ORARENOOS 122 [Top cone race holder To old the steering stom lock nv O7HAKZNOD4 123 [Washing kt (Meso) To restict woter entry during washing O7ORAKZNOOS ing sprocket remover To remove the timing sprocket from the cronkshaf [O7HHKO600 125 [Timing sprocket insalor Te insol he firing sprocket on the crankshaf. _[O7OFKO6002 126 [Crankshaft bearing driver To instal the cronkcose bearing O70HKO6003 127 | Crankshaft bearing collar To install crankshaft bearing and timing sprocket. | O7OHHKZAQ01 128 [Driver (RHS) crankshaft bearing To instal he crankshat bearing in HS) crankcase. [OTOHHKZAGO2 129 |Crankshaft installer adapter To install the crankshaft in the (RHS} crankcase. _ | O7OHHKZA003 130 [Muffler pl (Bish To esc water entry during wshing O70HHKZAO04 131 [Muffler plug (Small) To resirici water entry during washing. ‘O7OHHKO6004 132 [Hero integrate diagnostic nau For immobilizer diagnosis & key reisvaion. [HMCLO2T4AABAOT 133, [HDI wire harness For sme between insiument & bike wire horess. | HMCLO2T4AABAD2 134 [TPS testhomess To reset trot positon senso FMICLI2AAABADA 135 [Service stand ‘To park the splendor pro classic in upright position. | HMCLO415AADFO! 136 [Com sprocket driver Te roloe the com sprocket for TDC poston. __[HMCLO41519801 137 |Left crankshaft oil seal guide To remove crankshaft oil seal guide. HMCL1014AALBOT 136 [lef cronkshoft il seal intller Te install crankshaft el eal guide. HMCLIOT4AALBO? 139 | Right crankshaft oil seal installer To install crankshaft oil seal guide. HMCL1014AALBO3_ T40 | Flywheel puller Te remove the Thee! rom

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