Chapter 7. Specifications

Chapter 7. Specifications
Model(s)
900RL
xjcdadmin Thu, 06/27/2013 - 10:26

General Specifications

General Specifications
Model(s)
900RL
xjcdadmin Thu, 06/27/2013 - 10:26
1 Model Code Number 33F
2 Frame Starting Number 33F-000101
3 Engine Starting Number 33F-000101
4
a		 Dimensions:
Overall Length   		 2,190 mm (86.2 in)
b Overall Width 735 mm (28.9 in)
c Overall Height 1,240 mm (48.8 in)
d Seat Height 790 mm (31.1 in)
e
f		 Wheelbase
Minimum Ground Clearance		 1,480 mm (58.3 in) 150 mm ( 5.9 in)
5. a. Weight:
With Oil and Full Fuel Tank		 242 kg (534 lb)
6 Minimum Turning Radius 2,600 mm (102.4 in)
7
a		 Engine:
Engine Type   		 D.O.H.C., air-cooled, gasoline
b Cylinder Arrangement Forward-incline, parallel 4-cylinder
c Displacement 853 cm3 (52.05 cu.in)
d Bore x Stroke 67.0 x 60.5 mm (2.638 x 2.382 in)
e  Compression Ratio 9.6 : 1
f Compression Pressure 785 - 1,177 kPa (8.0 - 12.0 kg/cm2, 114-171 psi)
g Starting System Electric
8 Lubrication System
Pressure lubricated, Wet sump
9 Engine Oil Type or Grade
Above 15°C (60°F)

Below 5°C (40°F)

 SAE 20W40 type SE motor oil SAE 10W30 type SE motor oil
10.
a.		 Engine Oil Capacity
Periodic Oil Change		 2.5  L (2.2 Imp qt. 2.6 US qt)
b Oil Filter Replacement 2.8 L (2.5 Imp qt, 3.0 US qt)
c Total Amount 3.6  L (3.2 Imp qt, 3.8 US qt)
11 Final Gear Oil  
a Grade or Type SAE 80 API "GL-4" Hypoid gear oil
b Final Gear Case Oil Amount 0.2 L (0.18 impqt, 0.21 US qt)
12 Air Filter Dry type element
13. a. Fuel Type Regular gasoline
b Tank capacity 22.0 L (4.84 Imp gal, 5.81 US gal)
c  Reserve Amount 5.0 L (1.10 Imp gal, 1.32 US gal)
14 Carburetor  
a Type BS35 x 4
b Manufacturer MIKUNI
15 Spark Plug  
a Type BPR8ES
b Manufacturer NGK
c Gap 0.7 ~ 0.8 mm (0.028 — 0.032 in.)
16 Clutch Type Wet multiple disc
17. Transmission:  
a
b
c		 Primary Reduction System
Primary Reduction Ratio
Secondary Reduction System		 Spur gear
97/58 (1.672)
Shaft drive
d Secondary Reduction  
  Transmission output Type/teeth/ratio Spur gear, 48/37 (1.297)
  Middle gear case Type/teeth/ratio Bevel gear, 19/18 (1.055)
  Final gear case Type/teeth/ratio Bevel gear, 32/11 (2.909)
e Transmission Type Constant mesh, 5-speed drum shifter
f Operation Left foot operation
g Gear Ratios  
  1st 35/16 (2.187)
  2nd 30/20 (1.500)
  3rd 30/26 (1.153)
  4th 28/30 (0.933)
  5th 26/32 (0.812)
18 Chassis:  
a Frame Type Tubular steel double cradle
b  Caster Angle 27°
c Trail 114 mm (4.49 in)
19
a
b
c
d		 Tire
Type
Tire Size (F)
Tire Size (R)
Manufacturer		 Tubeless 100/90 V18 120/90 V18 PIRELLI, BRIDGESTONE
20
a		 Tire Pressure
UP to 90 kg (198 lb) load*                     (F)		 (Cold pressure)
226 kPa (2.3 kg/cm2, 32 psi)     
                                                             (R) 245 kPa (2.5 kg/cm2, 36 psi)
b 90 kg (198 lb) - 194 kg (428 lb) load*     (F) 245 kPa (2.5 kg/cm2, 36 psi)
                                                             (R) 284 kPa (2.9 kg/cm2, 42 psi)
c High-speed Riding                                (F) 245 kPa (2.5 kg/cm2, 36 psi)
                                                             (R) 284 kPa (2.9 kg/cm2, 42 psi)
  *Toral weight of accessories, etc. excepting motorcycle  
21.
a.
b.
c.
d.		 Brake
Front Brake Type
Operation
Rear Brake Type
Operation		 Dual Hydraulic disc
 Right hand
Single hydraulic disc Right foot
22 Suspension   
a Front Suspension Telescopic fork
b. Rear Suspension Swingarm
23 Shock Absorber  
a Front Shock Absorber Oil damper, air and coil spring
b Rear Shock Absorber Oil damper, gas and coil spring
24.
a.
b.		 Wheel Travel
Front Wheel Travel
Rear Wheel Travel		 150 mm (5.9 in)
102 mm (4.0 in)
25.
a.
b.
c.
d.		 Electrical
ignition System
Generator System
Battery Type or Model
Battery Capacity		 Transistor ignition
A.C. generator
YB14L
12V 14AH
26 Headlight Type HALOGEN
27
a
b
c
d
e
f		 Bulb Wattage x Pcs
Headlight
Turn light
Tail/Brake light
Meter light
License light
Auxiliary light		 60W/55W x 1
27W x 4
8W/27W x 2
3.4W x 6
8W x 2
3.4W x 1
28.
a.
b.
c.
d.		 Indicator Light Wattage x Pcs
NEUTRAL
HIGH BEAM
TURN
OIL		 3.4W x 1
3.4W x 1
3.4W x 2
3.4W x 1

Engine Specifications

Engine Specifications
Model(s)
900RL
xjcdadmin Thu, 06/27/2013 - 10:26

1.

a. b.

Cylinder

Head Volume
Warp Limit

 

 

31.5 - 32.3 cm3 (1.92 - 1.97 cu.in)
<0.03 mm (0.0012 in)>
Lines indicate straightedge measurement

2. a. b. c. d.

Cylinder
Material
Bore Size
Taper Limit
Out-of-round Limit


Aluminum alloy with cast iron sleeve
67.0 mm (2.638 in)
<0.05 mm (0.0020 in)>
<0.01 mm (0.0004 in)>

3.
a.

b. c. d.

Camshaft
Drive Method

Cam Cap Inside Diameter
Camshaft Outside Diameter
Shaft-to-cap Clearance
Chain drive Center
25+0.021-0 mm  (0.984+0.0008-0 in)
25-0.020-0.33 mm  (0.984-0.0008-0.0013 in)
0.020 ~ 0.054 mm  
 (0.0008 - 0.0021 in)

e.

Cam Dimensions

Intake

"A"
"B"
"C"

36.75 - 36.85 mm (1.447 - 1.451 in)
28.05 - 28.15 mm (1.104 - 1.108 in)
8.75 — 8.85 mm (0.344 — 0.348 in)

Exhaust

"A"
"B"
"C"

36.25 — 36.35 mm (1.427 — 1.431 in)
28.55 - 28.65 mm (1.124 - 1.128 in)
8.25 — 8.35 mm (0.325 - 0.329 in)

f.

Open
Close

Open
Close

B.T.D.C. 38°
A.B.C.D. 58°

B.B.D.C. 66°
A.T.D.C. 26°

Overlap

a = 64°

g.

h. i.

Cam Chain Type/Number of Links
Cam Chain Adjustment Method

BUSH-CHAIN/120
Automatic

4.
a.

b.

Valve, Valve Seat, Valve Guide
Valve Clearance (Cold)                        INTAKE.
                                                        EXHAUST.

Valve Dimensions

0.11 — 0.15 mm (0.0043 - 0.0059 in)
0.16 — 0.20 mm (0.0063 — 0.0079 in)
 

 

"A" Head Dia.               IN.
                                  EX.
"B" Face Width              IN.
                                  EX.
"C" Seat Limit Width      IN.
                                  EX.

36.1 ± 0.1 mm (1.42 ± 0.004 in)
30 ± 0.1 mm (1.18 ± 0.004 in)
2.3 mm (0.091 in)
2.3 mm (0.091 in)
1 ± 0.1 mm (0.039 ± 0.004 in)
1 ± 0.1 mm (0.039 ± 0.004 in)
 

"D" Margin Thickness Limit IN.
                                      EX.

0.7 mm (0.028 in)
0.7 mm (0.028 in)

c.

Stem Outside Diameter IN.

7-0.10-0.025mm (0.2756 -0.0004-0.0010 in)

 

                                  EX.

7-0.25-0.040 mm (0.2756 -0.0010-0.0016 in),

d

Guide Inside Diameter   IN.

7+0.12-0. mm (0.2756 -0.0005-0.in)
 

                                   EX.

7+0.12-0. mm (0.2756 -0.0005-0. in)

e.

Stem-to-guide Clearance IN.

0.010 — 0.037 mm (0.0004 - 0.0015 in)
 

                                    EX.

0.025 — 0.052 mm (0.0010 - 0.0020 in)

f.

Stem Runout Limit

<0.03 mm (0.0012 in)>

g-

Valve Seat Width Standard <Limit>

0.9 - 1.1 mm (0.035 - 0.043 in)
<2.0 mm (0.080 in)>

5.

a.

Valve Spring Free Length
Inner Spring              IN.
                               EX.
Outer Spring              IN.
                               EX.


35.9 mm (1.413 in)
35.9 mm (1.413 in)
39.5 mm (1.555 in)
39.5 mm (1.555 in)

b.

Spring rate
Inner Spring              IN.

                               EX.


K, : 2.36 kg/mm (132 lb/in)
K2 : 1.84 kg/mm (103 lb/in)
K, : 2.36 kg/mm (132 lb/in)
K2 : 1.84 kg/mm (103 lb/in)
 

Outer Spring              IN.
                               EX.


K, : 4.58 kg/mm (256 lb/in)
K2 : 3.464 kg/mm (194 lb/in)
K, : 4.58 kg/mm (256 lb/in)
K2 : 3.464 kg/mm (194 lb/in)

c.

Compression Length (Valve Closed)
Inner Spring              IN.
                               EX.
Outer Spring              IN.
                               EX.


31.0 mm (1.220 in) 3
31.0 mm (1.220 in)
34.0 mm (1.339 in)
34.0 mm (1.339 in)

d.

Compression Force (Valve Closed) Inner Spring                      IN.
                               EX.
Outer Spring              IN.
                               EX.


8.1 - 9.9 kg (17.9 - 21.8 lb)
8.1 - 9.9 kg (17.9 - 21.8 lb)
17.6 — 20.6 kg (38.8 — 45.4 lb)
17.6 — 20.6 kg (38.8 — 45.4 lb)

e.

Tilt Limit


Inner Spring IN. & EX.
Outer Spring IN. & EX.

2.5°  1.7 mm (0.067 in)
2.5°  1.7 mm (0.067 in)

f.

Direction of Winding (Top View)

Intake

Exhaust
 

6.

a.

Piston Piston Size/Measuring Point (A)

67.0 mm (2.638 in)/7.8 mm (0.307 in)
(From bottom line of piston skirt)
   

b.

c.

d.

Clearance between Piston & Cylinder
Limit
Oversize                   1 st
                               2nd
                               3rd
                               4th
Piston Pin Hole Off-Set

0.03 - 0.05 mm (0.0012 - 0.0020 in)
<0.1 mm (0.0039 in)>
 -
67.50 mm (2.667 in)
-
68.00 mm (2.677 in)
0.5 mm (0.02 in) Inside

7.
a.

Piston Ring
Sectional Sketch

  
   

Top Ring

B = 1.2-0.01-0.03 mm (0.47-0.0004-0.0012in)
T = 2.7 ± 0.1 mm (0.106 ± 0.004 in)
   

2nd Ring

B = 1.2-0.01-0.03 mm (0.472-0.0004-0.0012 in)
T = 2.7 ± 0.1 mm (0.106 ± 0.004 in),
   

Oil Ring


B = 2.5 mm (0.098 in)

T = 2.8 ± 0.15 mm (0.110 ± 0.0059 in)

b.

End Gap (Installed) Limit

Top Ring

2nd Ring

Oil Ring

0.15 - 0.35 mm (0.0059 - 0.0138 in)
<1.0 mm (0.039 in)>
0.15 - 0.35 mm (0.0059 - 0.0138 in)
< 1.0 mm (0.039 in)>
0.3 - 0.9 mm (0.012 - 0.035 in)
< 1.5 mm (0.059 in)>

c

Side Clearance
Limit

Top Ring

2nd Ring

0.03 - 0.07 mm (0.0012 - 0.0028 in)
<0.15 mm (0.0059 in)>
0.02 — 0.06 mm (0.0008 — 0.0024 in)
<0.15 mm (0.0059 in)>

d.

Plating or Coating

Top Ring
2nd Ring
Oil Ring

Chrome plated, Ferox coating
Parkerizing
Chrome plated, Ferox coating

8.
a.
b.

Connecting Rod
Oil Clearance
Color Code

  

0.016 - 0.040 mm (0.0006 - 0.0016 in)
1. Blue, 2. Black, 3. Brown, 4. Green

9. a.

b. c. d. e.

Crankshaft
Crank Width "A"

 

Assembly Width "B"

Deflection Limit "C"
Big End Side Clearance "D"

Journal Oil Clearance


A, = 56.15 mm (2.211 in)
A2 = 59.20 mm (2.331 in)
A3 = 60.45 mm (2.380 in)
A4 = 56.45 mm (2.222 in)
341.4 ± 0.6 mm
(13.44 ± 0.024 in)
<0.03 mm (0.0012 in)>
0.16 - 0.26 mm
(0.0063 - 0.0102 in)
0.020 - 0.044 mm (0.0008 - 0.0017 in)

f.

Color Code - Corresponding Size                                Blue


1.5+0.006+0.002mm(0.0591+0.00024+0.00008in
 

Black

1.5+0.002-0.002mm(0.0591+0.00008-0.00008in)

Brown

1.5-0.002-0.006mm(0.0591-0.00008-0.00024in)

Green

1.5-0.006-0.010mm(0.0591-0.00024-0.00039in)

Yellow

1.5-0.010-0.014mm(0.0591-0.00039-0.00055in)

10. a. b.

c. d.

e.
f.

g
h.

i.

j-

Clutch
Friction Plate Thickness/Quantity
Wear Limit

Clutch Plate Thickness/Quantity
Warp Limit

Clutch Spring Free Length/Quantity
Minimum Length

Primary Reduction Gear Backlash Tolerance
Primary Drive Gear
Backlash Number
Primary Driven Gear
Backlash Number
Clutch Release Method

3.0 ± 0.1 mm (0.12 ± 0.004 in)/8
<2.8 mm (0.11 in)>

2.0 ± 0.1 mm (0.080 ± 0.004 in)/7
<0.05 mm (0.002 in)>

44.0 mm (1.73 in)/5
43.0 mm (1.69 in)

116

87 - 93

25 — 31
Rack & Pinion pull, Outer pull

11. a.

Transmission
Main Axle Run-out Limit


<0.08 mm (0.0031 in)>

12
a.

Shifter
Shifter Type


Guide bar

13. a. b. c. d.

Carburetor
Type/Manufacturer/Quantity
I.D. Mark
Throttle Valve Size
Venturi Size


BS35/MIKUNI/4
31A 00
ø35 mm (01.38 in)
ø31 mm (01.22 in)

e.

f.

g

h.

i.

j-

k.

I.

m.

n.

o.

P-

q-

Main Jet

Main Air Jet

Jet Needle

Needle Jet

Throttle Valve

Pilot Jet

Pilot Air Jet

Pilot Screw (turns out)

Pilot Outlet Size

Starter Jet

Valve Seat Size

Fuel Level

Float Height

(MJ.)

(M.A.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(P.A.J.)

(P.S.)

(P.O.)

(G.S.)

(V.S.)

(F.L)

(F.H.)

#102.5

#45

4HZ26-3

Y-0 (#318)

135

#40

#160

Pre-set 2 turns

00.8

#32.5

Φ2.0

5 ± 1 mm (0.20 ± 0.04 in)

22.3 ± 0.5 mm (0.9 ± 0.02 in)

r.

s.

Engine Idling Speed

Vacuum Pressure at Idling Speed

1,100 ± 50 r/min

225 - 235 mmHg (8.85 — 9.25 inHg)

14.
a.
b.
c.
d.
e.
f.

g-

Lubrication System:
Oil Filter Type
Oil Pump Type
Tip Clearance
Side Clearance
Bypass Valve Setting Pressure
Relief Valve Operating Pressure

Lubrication Diagram

Paper filter
Trochoid pump
0.03 — 0.09 mm (0.0012 — 0.0035 in)
0.03 — 0.08 mm (0.0012 — 0.0031 in)
98 ± 20 kPa (1.0 ± 0.2 kg/cm2. 14.2 ± 2.8 psi)
490 ± 50 kPa (5.0 ± 0.5 kg/cm2. 71.1 ± 7.1 psi)

15.

Middle Gear Backlash

0.1 - 0.2 mm (0.004 ~~ 0-008 in)

16.

Final Gear Backlash

0.1 — 0.2 mm (0.004 - 0.008 in)

17.

Crankcase Tightening Sequence

  

LOWER CASE

UPPER CASE

Tightening Torque:

 8 mm bolt: 24 Nm (2.4 mkg. 1 7 ft-lb)  6 mm bolt: 12 Nm (1.2 mkg, 8.7 ft-lb)

18.

Tightening Torque

    

Part to be tightened

Part name

Thread size

Q'ty

Tightening torque

Remarks

Nm

mkg

ft lb

ENGINE:

Camshaft cap

Bolt

M6x1.0

24

10     1.0    7.2

Tighten in stages

Cam chain (Front) (Rear)

Stud bolt Nut

Stud bolt Nut

M6x1.0
M6x1.0
M6x1.0
M6x1.0

2
2
2 2

5 0.    5         3.6

10      1.0      7.2
5       0.5       3.6
10      1.0      7.2

Apply oil Apply oil

Exhaust pipe

Stud bolt

M6x1.0

8

8       0.8       5.8

Apply oil

Oil passage blind plug

Screw

M6x1.0

1

7       0.7       5.1

  

YICS passage

Stud bolt
Nut
Blind plug

M8x1.25
M8x1.25
M12x1.25

2

2 2

15      1.5       11
20      2.0       14
22      2.2       16

Apply oil

Spark plug

—

M14X1.25

4

20      2.0       14

  

Cylinder head

Nut

M10x1.25

12

32      3.2       23

Apply oil

Cylinder head cover

Bolt

M6x1.0

8

10      1.0      7.2

  

Cam chain (Cylinder-Front)

Stud bolt

Nut

M8x1.25
M8x1.25

1

1

8        0.8      5.8
20      2.0       14

Apply oil

Connecting rod

Nut

M8x0.75

8

38      3.8       27

 Apply Molybedenum
disulfide grease

Cam sprocket

Bolt

M7x1.0

4

20      2.0       14

  

Cam chain tensioner

Bolt

M6x1.0

2

10      1.0      7.2

  

Cam chain tensioner guide

Bolt

M8x1.25

1

3        0.3     2.2

  

Oil Pump cover

Screw

M6x1.0

4

7        0.7      5.1

  

Strainer housing

Screw

M6x1.0

3

7        0.7      5.1

  

Oil pump

Bolt

M6x1.0

3

12      1.2      8.7

  

Oil filter

Union bolt

M20x1.5

1

15      1.5      11

  

Engine drain bolt

Bolt

M14x1.5

1

43      4.3      31

  

Strainer cover

Bolt

M6x1.0

13

12      1.2      8.7

  

Oil pump sprocket

Bolt

M6x1.0

1

12      1.2      8.7

  

Buffle plate

Screw

M6x1.0

3

7        0.7      5.1

  

Oil cooler adapter plate

Union bolt

M20x1.5

1

50      5.0       36

  

Part to be tightened

Part name

Thread size

Q'ty

Tightening torque

Remarks

Nm

mkg

ft-lb

Oil cooler hose and adapter

Bolt

M6x1.0

4

12

1.2

8.7

  

Oil hose

Bolt

M6x1.0

1

12

1.2

8.7

  

Oil cooler

Bolt

M6x1.0

3

10

1.0

7.2

  

Oil cooler hose clamp

Nut

M8x1.25

1

10

1.0

7.2

  

Carburetor joint

Bolt

M6x1.0

8

12

1.2

8.7

  

Air filter case cover

Screw

M6xt.O

4

5

0.5

3.6

  

Air filter case and frame

Bolt

M6x1.0

3

5

0.5

3.6

  

Exhaust pipe joint band

Bolt

M8x1.25

6

20

2.0

14

  

Exhaust pipe ring nut

Nut

M6x1.0

8

10

1.0

7.2

  

Exhaust pipe and frame

Bolt

M1 0x1.25

2

25

2.5

18

  

Cylinder

Stud bolt Bolt

M10x1.25 M10X1.25

8

4

20 20

2.0 2.0

14

14

  

Crankcase

Bolt Bolt

M8x1.25 M6x1-0

19

19

24

12

2.4 1.2

17 8.7

  

Bearing plate stopper

Screw

M8x1.25

4

25

2.5

18

  

Breaker cover

Screw

M6x1.0

8

8

0.8

5.8

  

Generator cover .

Bolt

M6x1.0

3

12

1.2

8.7

  

Generator housing bearing

Screw

M6x1.0

3

10

1.0

7.2

  

Change cover

Bolt

M6x1.0

10

12

1.2

8.7

  

Drive shaft housing bearing

Bolt

M6x1.0

3

12

1.2

8.7

  

Clutch cover

Bolt

M6x1.0

10

12

1.2

8.7

  

Clutch cable holder

Bolt

M6x1.0

2

12

1.2

8.7

  

Middle drain bolt

Bolt

M8x1.25

1

16

1.6

11

  

Breather pipe 1

Screw

M6x1.0

3

7

0.7

5.1

  

Breather pipe 2

Screw

M6x1.0

4

7

0.7

5.1

  

Main gallary blind plug

Plug

M20X1.5

2

12

1.2

8.7

Apply oil

Stopper plate

Bolt

M6x1.0

1

10

1.0

7.2

  

Clutch starter outer

Bolt

M8x1.25

3

25

2.5

18

  

Upper guide

Bolt

M6x1.0

3

10

1.0

7.2

  

Clutch pressure plate

Bolt

M6x1.0

5

8

0.8

5.8

  

Clutch boss

Nut

M20X1.0

1

70

7.0

50

  

Drive shaft bearing

Nut

M34x1.0

1

110

11.0

80

  

Part to be tightened

Part name

Thread size

Q'ty

Tightening torque

Remarks

Nm

mkg

ft ib

Driven shaft bearing

Nut

M65x1.5

1

110

11.0

80

  

Middle gear flange

Nut

M14x1.5

1

90

9.0

65

  

Housing bearing

Bolt

M8x1.25

4

25

2.5

18

  

Stopper plate

Screw Bolt

M6x1.0 M6x1.0

1

1

7 8

0.7 0.8

5.1 5.8

  

Change pedal

Bolt

M6x1.0

1

10

1.0

7.2

  

Change pedal link

Nut

M6x1.0

2

10

1.0

7.2

  

A.C. Generator

Bolt

M10x1.25

1

55

5.5

40

  

Pick-up coil base

Screw

M6x1.0

2

8

0.8

5.8

  

Rotor

Bolt

M8x1.25

1

24

2.4

17

  

Brush

Screw

M6x1.0

2

8

0.8

5.8

  

Timing plate

Screw

M6x1.0

1

8

0.8

5.8

  

Starter motor

Bolt

M6x1.0

2

7

0.7

5.1

  

Oil level switch

Bolt

M6x1.0

2

7

0.7

5.1

  

Drive shaft

U Nut

M14x1.5

1

110

11.0

80

  

Bearing cap

Bolt Nut

M10x1.25 M8x1.25

2

6

23 23

2.3 2.3

17

17

  

Oil mount screw

Plug

M14x1.5

1

23

2.3

17

  

Oil drain screw

Plug

M14x1.5

1

23

2.3

17

  

Bearing retainer

—

M65x1.5

1

110

11.0

80

  

Final gear case

Stud bolt Stud bolt

M10x1.25 M8x1.25

4

6

17 9

1.7

0.9

12 6.5

  

Chassis Specifications

Chassis Specifications
Model(s)
900RL
xjcdadmin Thu, 06/27/2013 - 10:26

1

Steering System
Steering Bearing Type
Bearing Type

Lock-to-iock Angle


Upper Lower

Taper roller bearing

KOYO 32005
KOYO 32006
40°

2.
a.
b.
c.

 

d.
e.

f.

g

Front Suspension
Front Fork Travel
Fork Spring Free Length
Spring Rate/Stroke

 


Optional Spring
Oil Capacity
or Oil Level

Oil Grade

Enclosed Air Pressure

K1

K2

150 mm (5.91 in)
522.5 mm (20.6 in)
7.2 N/mm (0.72 kg/mm, 40.3 lb/in)/
0 - 100 mm (0 - 3.94 in)
10.4 N/mm (1.04 kg/mm, 58.2 lb/in)/
100 — 150 mm (3.94 — 5.91 in)

No
286 ± 4 cm3
(10.1± 0.14 Imp oz, 9.67 ± 0.14 US oz)
164 mm (6.46 in)
(From top of inner tube fully compressed without spring.)
SAE 5W type SE motor oil or equivalent
39 kPa (0.4 kg/cm2, 5.7 psi)

3.
a.
b.
c.

d.
e.

Rear Suspension
Shock Absorber Travel
Spring Free Length
Spring Rate/Stroke

Optional Spring
Enclosed gas pressure

K1

K2


75 mm (2.95 in)
237 mm (9.33 in)
21.5 N/mm (2.15 kg/mm, 120.4 lb/in)/
0 -36 mm (0 - 1.42 in)
30.0 N/mm (3.0 kg/mm, 168.0 lb/in)/
36 — 75 mm (1.42 — 2.95 in)

No.
150 kPa (15 kg/cm2, 213 psi)

4.
a.

Rear Arm
Swingarm Free Play Limit


-End
-Side


1 mm (0.04 in)
1 mm (0.04 in)

5.
a.

b.

c.

Wheel
Front Wheel Type
Rear Wheel Type
Front Rim Size/Mat'l
Rear Rim Size/Material
Rim Runout Limit
- Vertical
- Lateral

  

Cast wheel
Cast wheel
MT 2.15 x 18/Aluminum
MT 2.75 x 18/Aluminum

<2.0 mm (0.08 in) >
<2.0 mm (0.08 in) >

6.
a.

b.

Disc Brake
Type

Outside Dia. x Thickness

Front
Rear
Front
Rear

Dual disc
Single disc
267 x 7.5 mm (10.5 x 0.30 in)
267 x8.5 mm (10.5 x 0.33 in)

c.

Pad Thickness
Front
Rear

Limit
Front
Rear

  


5.5 mm (0.22 in)
5.5 mm (0.22 in)

<0.5 mm (0.020 in) >
<0.5 mm (0.020 in) >

d.

e.

f.

Master Cylinder Inside Dia.

Caliper Cylinder Inside Dia.

Brake Fluid Type

Front
Rear
Front
Rear

15.87 mm (0.62 in)
12.7 mm (0.50 in)
42.85 mm (1.69 in) 4
2.85 mm (1.69 in)
D0T#3

7.
a.
b.
c.

Brake Lever & Brake Pedal
Brake Lever Free Play
Brake Pedal Free Play
Brake Pedal Position


5.0 — 8.0 mm (0.2 — 0.3 in)
20 — 30 mm (0.8 - 1.2 in)
30 mm (1.2 in)
(Vertical height below footrest top.)

8.

Clutch Lever Free Play

2 — 3 mm (0.08 -0.12 in)

Recommended combinations of the front fork and rear shock absorber settings. Use this table as guidance to meet specific riding and motorcycle load conditions.

 

Front fork

Rear shock absorber

Loading condition
 

Air pressure

Spring seat

Damping adjuster turns out*

Solo rider

With passenger

With

accessory

equipments

With

accessory

equipments

and passenger

1

39.2 — 78.5 kPa

(0.4 - 0.8 kg/cm2,

5.7 - 11.4 psi)

6

O

      

2

39.2 — 78.5 kPa

(0.4 - 0.8 kg/cm2, 5.7 - 11.4 psi)

4

  

O

    

3

58.8 — 98.1 kPa

(0.6 - 1.0 kg/cm2,

8.5 - 14.2 psi)

4

    

O

  

4

78.5 ~~ 118 kPa

(0.8 - 1.2 kg/cm2,

11.4 - 17.1 psi)

3

      

O

Each numeral shows the damping value which can be set when the pointer is aligned with the individual slit in the spring seat. The damping adjuster may be further turned for a softer or harder damping; in each of the above settings, itis recommended that the damping be adjusted by one (1) or two (2) clicks on the softer side and one (1) click on the harder side.

1 9. Tightening Torque

      

Parts to be tightened

Thread size

Tightening torque

Remarks

Nm

nrkg

ft-lb

CHASSIS:

          

Front wheel axle and nut

M14x 1.5

78

7.8

50

  

Front fender and front fork

M6 x 1.0

9

0.9

6.5

  

Handle crown and inner tube

M8 x 1.25

20

2.0

14

  

Handle crown and steering shaft

M25 x 1.0

110

11.0

80

  

Under bracket and inner tube

M8 x 1.25

23

2.3

17

  

Front fork cylinder and outer tube

M8 x 1.25

23

2.3

17

  

Brake caliper (Front and rear)

M10 x 1.25

35

3.5

25

  

Front fork and axle holder

M8 x 1.25

20

2.0

14

  

Anti-nose dive and front fork

M5 x 0.8
M6 x 1.0

5
7

0.5
0.7

3.6
5.1

  

Brake disc and wheel hub

M8x 1.25

20

2.0

14

  

Brake caliper and bleed screw (Front and rear)

M8 x 1.25

6

0.6

4.3

  

Anti-nose dive and bleed screw

M8 x 1.25

6

0.6

4.3

  

Union bolt (Front and rear)

M10 x 1.25

26

2.6

19

  

Brake pipe and joint

M10x 1.0

19

1.9

13

  

Master cylinder and master cylinder cap

M5 x 0.8

2

0.2

1.4

  

Handle crown and handlebar

M12 x 1.25

93

9.3

67

  

Handlebar and grip bar

M10x 1.25

50

5.0

36

  

Grip bar and grip end

M18 x 1.5

26

2.6

19

  

Front brake master cylinder and master cylinder bracket

M6 x 1.0

9

0.9

6.5

  

Fuel sender unit and fuel tank

M5 x 0.8

4

0.4

2.9

  

Engine mounting bolt Front, upper
                               Front, lower
                               Rear

M10 x 1.25
M10 x 1.25
M12 x 1.25

42
42
70

4.2
4.2
7.0

30
30
50

  

Engine stay and frame

M8x 1.25

20

2.0

14

  

Pivot shaft and rear arm

M22 x 1.5

6

0.6

4.3

  

Pivot shaft and lock nut

M22 x 1.5

100

10.0

72

  

Rear shock absorber and frame

M10 x 1.25

30

3.0

22

  

Rear shock absorber and rear arm

M10x 1.25

30

3.0

22

  

Rear shock absorber and housing gear

M10 x 1.25

30

3.0

22

  

Rear wheel axle and nut

M14x 1.5

105

10.5

75

  

Parts to be tightened

Thread size

Tightening torque

Remarks

Nm

rrvkg

ft-lb

Middle gear flange and cross joint

M8 x 1.25

44

4.4

32

  

Frame and muffler bracket

M10 x 1.25

42

4.2

30

  

Rear footrest and muffler bracket

M10 x 1.25

42

4.2

30

  

Rear brake master cylinder and frame

M8 x 1.25

20

2.0

14

  

Compression bar and rear arm

M10 x 1.25

30

3.0

22

  

Compression bar and caliper bracket

M10 x 1.25

30

3.0

22

  

Rear stay and frame

M8 x 1.25

23

2.3

17

  

Electrical Specifications

Electrical Specifications
Model(s)
900RL
xjcdadmin Thu, 06/27/2013 - 10:26

1.

Voltage

12V

2.
a. b.

Ignition System
Ignition Timing (B.T.D.C.)
Advanced Timing (B.T.D.C.)

5°/1,050 r/min
40°/5,500 r/min
   

 

c.

Advancer Type

Electrical type

3.

a. b.

T.C.I.

Pick up Coil Resistance (Color) T.C.L Unit-Model/Manufacturer

120 Ω ± 20% at 20°C (68°F) (O-B, Gy-B) TID14-19/HITACHI

4. a. b.
 

c. d.

Ignition Coil
Model/Manufacturer
Minimum Spark Gap
 

Primary Winding Resistance
Secondary Winding Resistance

CM12-20/HITACHI
6 mm (0.24 in) or more at 500 r/min
(19 KV/100 r/min at 6V, 16 KV/9,500 r/min a14V)

2.7Ω ± 10%at20°C (68°F)
13.2KΩ ± 20% at 20°C (68°F)

5.
a. b. c.

Charging System
Type
Model/Manufacturer
Output

A.C. Generator
LD119-08/HITACHI
14V 18A at 5,000 r/min
   

 

d. e. f.
g
h.

Field (Inner) Coil Resistance (Color)
Armature (Outer) Coil Resistance (Color)
Brush-Overall Length
—Wear Limit
—Spring Pressure

4.0 n ± 10% at 20°C (68°F) (G-Br)
0.46 ft ± 10% at 20°C (68°F) (W-W)
17 mm (0.67 in)
10 mm (0.39 in)
190 - 360 g (6.7 - 12.7 oz)

6.
a.
b.
c.

Voltage Regulator
Type
Model/Manufacturer
No Load Regulated Voltage

Field control type
SH233-1 2/SHINDENGEN
14.2 ~ 14.8V

7.
a.
b.
c.

Rectifier
Model/Manufacturer
Capacity
Withstand Voltage

SH233-1 2/SHINDENGEN
35A
320V

8.
a.
b.

Battery
Capacity
Specific Gravity

12V 14AH
1,280

9.
a.
b.
c.
d.

e.

f.

g

h.
i.
j

Electric Starter System
Starter Motor-Model/Manufacturer
-Output
Armature Coil Resistance
Brush-Overall Length
Limit
Spring Pressure

Commutator Dia.
Wear Limit
Mica Undercut

Starter Switch Manufacturer
Amperage Rating
Coil winding resistance

Constant mesh type
ADB4D2/NIPPONDENSO
0.6 kw
0.014 Ω ± 6% at 20°C (68°F)
12 mm (0.47 in)
<8.5 mm (0.33 in)>
800±150 g
(28.22 ± 5.29 oz)
28 mm (1.1 in)
<27 mm (1.06 in) >
0.6 ± 0.2 mm
(0.024 ± 0.008 in)
22U/HONDA LOCK
150A
3.4ft at 20°C (68°F)

10.
a.
b.
c.

Horn
Type/Quantity
Model/Manufacturer
Maximum-Amperage

 

Plane type/2
CF-12/NIKK0
2.5A

11.
a.
b.
c.
d.
e.

Flasher Relay
Type
Model/Manufacturer
Self Cancelling Device
Flasher Frequency
Wattage

Condenser type
FU249CD/NIPPONDENSO
Yes (Except Germany)
85 ± 10 cycle/min
27W x 2 + 3.4W

12.
a.

Self-Cancelling Unit
Model/Manufacturer

1A0/MATSUSHITA

13.
a.

Oil Level Switch
Manufacturer

4H7/NIPPONDENSO

14.
a.
b.

Fuel Gauge
Manufacturer
Sender Unit Resistance
-Full
-Empty

31A/NIPPON SEIKI

2 - 12Ω at 20°C (68°F)
87.5 - 102.5Ω at 20°C (68°F)

15.
a.
b.

Starting-Circuit Cut-Off Relay
Model/Manufacturer
Coil Winding Resistance

12R/0MR0N
75 0 ± 10%at20°C (68°F)

16.
a.
b.

 

Circuit Breaker
Type
Amperage for Individual Circuit
Main
Headlight
Signal
Ignition
Reserve

Fuse

30A/1
10A/1
10A/1
10A/1
30A/1 and 10A/1

 

General Torque Specifications

General Torque Specifications
Model(s)
900RL
xjcdadmin Thu, 06/27/2013 - 10:26

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.

A (Nut)

B (Bolt)

General torque specifications

Nm

m-kg

ft lb

10 mm

6 mm

6

0.6

4.5

12 mm

8 mm

15

1.5

11

14 mm

10 mm

30

3.0

22

17 mm

12 mm

55

5.5

40

19 mm

14 mm

85

8.5

61

22 mm

16 mm

130

13.0

94

A: Distance across flats B: Outside thread diameter

DEFINITION OF UNITS

Unit

Read

Definition

Mesure

mm
cm

Millimeter
centimeter

10-3 meter
10-2 meter

Length
Length

kg

kilogram

103 gram

Weight

N

Newton

1 kg x m/sec2

Force

Nm
m-kg

Newton meter
Meter kilogram

N x m
m x kg

Torque
Torque

Pa
N/mm

Pascal
Newton per millimeter

N/m2
N/mm

Pressure
Spring rate

L
cm3

Liter
Cubic centimeter

  

Volume or Capacity

r/min

Rotation per minute

  

Engine Speec