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DRIVE TRAIN COMPONENTS (cont)
Part
Oil Fill/Level Plug
Wheel (aluminum lug nut)
Wheel (black lug nut)
Bead Lock (Limited)
ENGINE/TRANSMISSION
Front Engine Through-Bolt
Rear Engine Through-Bolt
Clutch Cover/Housing
Assembly****
Crankcase Half (6 mm)
Crankcase Half (8 mm)
Cylinder Head (Cap Screw)
Cylinder Head Nut (6 mm)
Cylinder Head Nut (8 mm)
Valve Cover
Driven Clutch Bolt**
Driven Cam
Drive Clutch Bolt
Drive Clutch Cover
Magneto Cover
Crankshaft Spacer
Oil Pump Drive Gear**
Rotor/Flywheel Nut**
Cam Sprocket**
V-Belt Cover
Secondary Drive Gear Nut*
Shift Cam Stopper Support
Shift Cam Stopper Spring
Shift Cam Plate
Speed Sensor Housing
Starter Motor
Oil Pump Housing
Oil Strainer Cap
Intake Boot Clamp
Starter One-Way Clutch**
Fuel Rail
Air Filter Housing
Ground Wire
Stator Coil
Stator Coil
*w/Red Loctite #263***w/Green Loctite #270
**w/Red Loctite #271 ****w/"Patch-Lock"
*****w/Primer #7649 and Loctite #277
4
Torque
Part Bolted To
ft-lb N-m
16
Drive
80
Hub (20 ft-lb increments)
60
11
20
Frame
40
40
10
Crankcase
10
Crankcase
21
20
(step 2)
30
(final)
37
10
19
8.5
Input Shaft
60
11
Crankshaft
60
Drive Clutch
10
Crankcase
10
Crankshaft
28
Crank Balancer Shaft
62
Crankshaft
107
Camshaft
10
Inner Clutch Cover
9.5
200
Engine
8.5
8.5
Shift Cam Stopper
8.5
Shift Cam Shaft
8.5
Crankcase
9.5
10
Crankcase
8
11
Intake Boot
30
in.-lb
Rotor/Flywheel
26
Engine
6
Engine
6
Engine
8
Magneto Cover (New)
15
Magneto Cover (Original)
13
Torque Conversions
(ft-lb/N-m)
22
108
81
15
ft-lb
N-m
ft-lb
1
1.4
26
27
2
2.7
27
54
3
4.1
28
54
4
5.4
29
14
5
6.8
30
6
8.2
31
14
7
9.5
32
28
8
10.9
33
27
9
12.2
34
41
50
10
13.6
35
14
11
15
36
25
12
16.3
37
11.5
13
17.7
38
81
14
19
39
15
15
20.4
40
81
16
21.8
41
14
17
23.1
42
14
18
24.5
43
38
19
25.8
44
84
20
27.2
45
145
21
28.6
46
14
22
29.9
47
13
23
31.3
48
270
24
32.6
49
25
34
50
11.5
11.5
11.5
Drive Belt Break-In
11.5
Procedure
13
14
11
New drive belts require a break-in period of approxi-
15
mately 25 miles. During this period, drive the vehicle for
3.4
25 miles at 3/4 throttle or less while varying throttle posi-
tion (but not exceeding 40 mph). By varying throttle
35
position, the exposed cord on the side of a new belt will
8
be conditioned allowing the drive belt to gain its opti-
8
mum flexibility and will extend drive belt life.
11
20
18
Gasoline - Oil - Lubricant
FILLING GAS TANK
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the gas tank near any open flames or with
the engine running. DO NOT SMOKE while filling the
gas tank.
Since gasoline expands as its temperature rises, the gas
tank must be filled to its specified capacity only. Expan-
sion room must be maintained in the tank particularly if
the tank is filled with cold gasoline and then moved to a
warm area.
N-m
ft-lb
N-m
ft-lb
35.4
51
69.4
76
36.7
52
70.7
77
38.1
53
72.1
78
39.4
54
73.4
79
40.8
55
74.8
80
42.2
56
76.2
81
43.5
57
77.5
82
44.9
58
78.9
83
46.2
59
80.2
84
47.6
60
81.6
85
49
61
83
86
50.3
62
84.3
87
51.7
63
85.7
88
53
64
87
89
54.4
65
88.4
90
55.8
66
89.8
91
57.1
67
91.1
92
58.5
68
92.5
93
59.8
69
93.8
94
61.2
70
95.2
95
62.6
71
96.6
96
63.9
72
97.9
97
65.3
73
99.3
98
66.6
74
100.6
99
68
75
102
100
N-m
103.4
104.7
106.1
107.4
108.8
110.2
111.5
112.9
114.2
115.6
117
118.3
119.7
121
122.4
123.8
125.1
126.5
127.8
129.2
130.6
131.9
133.3
134.6
136
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Troubleshooting
