MOTORCYCLE

ISSUE NO. : M-Y-0003

DATE : May 20, 2014
PAGE : 1 OF 2

SUBJECT : ADDITIONAL MODEL INFORMATION

APPLICABLE MODEL : DR200SL5
EFFECTIVE ENGINE OR FRAME NO. : DR200SL5 E- 03, 28, 33, 71 JS1SH42A#F2100001
REFERENCE : E- 03, 28, 33, 71

This bulletin is to inform you of the service information for the above model.
When you service above model, please refer to the following service manuals.
Also, please note that the contents indicated below in such manuals should be
replaced by those in the attached sheet.
Please circulate this information to your dealers.

CORRESPONDING SERVICE MANUALS

MANUAL NAME MANUAL NUMBER
DR200SE SERVICE MANUAL (BOOK) 99500-41143-01E
99500-41141-03E
DR200SE SERVICE MANUAL (CD-ROM) 99560-01461-01E

* Please use the service bulletin that is issued by Aug. 8. 2008, when using service
manual (99500-41140-01E) in CD-ROM.
We believe that this information will be useful in your service activities.

CONTENTS

INFORMATION LABELS ...................................................................ATTACHED SHEET: PAGE 1

SPECIFICATIONS .............................................................................ATTACHED SHEET: PAGE 2
PERIODIC MAINTENANCE CHART .................................................ATTACHED SHEET: PAGE 3
EXHAUST PIPE BOLTS AND MUFFLER BOLTS ............................ATTACHED SHEET: PAGE 4
CHASSIS BOLTS AND NUTS ...........................................................ATTACHED SHEET: PAGE 5
ENGINE REINSTALLATION..............................................................ATTACHED SHEET: PAGE 7
FRONT WHEEL .................................................................................ATTACHED SHEET: PAGE 8
REAR WHEEL AND REAR BRAKE ..................................................ATTACHED SHEET: PAGE 8
STEERING .........................................................................................ATTACHED SHEET: PAGE 9
CHARGING SYSTEM ......................................................................ATTACHED SHEET: PAGE 10
IGNITION SYSTEM..........................................................................ATTACHED SHEET: PAGE 12
SPEEDOMETER AND INDICATOR LIGHT.....................................ATTACHED SHEET: PAGE 15
WIRING DIAGRAM ..........................................................................ATTACHED SHEET: PAGE 16
WIRING HARNESS ROUTING ........................................................ATTACHED SHEET: PAGE 17
 MOTORCYCLE
ISSUE NO. : M-Y-0003
DATE : May 20, 2014
PAGE : 2 OF 2

THROTTLE CABLE AND CLUTCH CABLE ROUTING ..................ATTACHED SHEET: PAGE 19

SPEEDOMETER CABLE ROUTING ...............................................ATTACHED SHEET: PAGE 20
FUEL HOSE ROUTING....................................................................ATTACHED SHEET: PAGE 20
EVAP CANISTER HOSE ROUTING (If equipped) .........................ATTACHED SHEET: PAGE 21
FRONT BRAKE HOSE ROUTING ...................................................ATTACHED SHEET: PAGE 22
EXTERIOR PARTS CONSTRUCTION ............................................ATTACHED SHEET: PAGE 23
HANDLEBARS INSTALLATION .....................................................ATTACHED SHEET: PAGE 24
FRONT FOOTREST INSTALLATION..............................................ATTACHED SHEET: PAGE 25
SEAT RAIL INSTALLATION ...........................................................ATTACHED SHEET: PAGE 25
ELECTRICAL PARTS INSTALLATION...........................................ATTACHED SHEET: PAGE 26
TIGHTENING TORQUE ...................................................................ATTACHED SHEET: PAGE 27
SERVICE DATA...............................................................................ATTACHED SHEET: PAGE 29
 99500-41143-01E

GENERAL INFORMATION ATTACHED SHEET: PAGE 1 OF 30

INFORMATION LABELS

General warning label Manufacturer label (If equipped)

Safety plate (If equipped)

Noise label (If equipped)

License plate (If equipped)

Headlight cover

Tire information label Vacuum hose routing label (If equipped)

FWD
Swingarm

Manual notice label (If equipped)

Frame center cover

Battery caution label (If equipped) Information label (If equipped)

FWD
Left frame cover
 99500-41143-01E

GENERAL INFORMATION ATTACHED SHEET: PAGE 2 OF 30

SPECIFICATIONS
DIMENSIONS AND CURB MASS
Overall length ...................................................................................... 2 150 mm (84.6 in)
Overall width........................................................................................ 805 mm (31.7 in)
Overall height ...................................................................................... 1 185 mm (46.7 in)
Wheelbase .......................................................................................... 1 405 mm (55.3 in)
Ground clearance................................................................................ 260 mm (10.2 in)
Seat height .......................................................................................... 810 mm (31.9 in)
Curb mass ........................................................................................... 126 kg (278 lbs)
ENGINE
Type .................................................................................................... Four-stroke, air-cooled, OHC
Number of cylinders ............................................................................ 1
Bore..................................................................................................... 66.0 mm (2.60 in)
Stroke .................................................................................................. 58.2 mm (2.29 in)
Displacement....................................................................................... 199 cm3 (12.1 cu. in)
Compression ratio ............................................................................... 9.4 : 1
Carburetor ........................................................................................... MIKUNI BST31SS, single
Air cleaner ........................................................................................... Polyurethane foam element
Starter system ..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed............................................................................................ 1 500 100 r/min
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission ....................................................................................... 5 speed constant mesh
Gearshift pattern.................................................................................. 1-down, 4-up
Primary reduction ................................................................................ 3.157 (60/19)
Final reduction..................................................................................... 3.000 (45/15)
Gear ratios, Low............................................................................... 3.000 (33/11)
2nd ............................................................................... 1.933 (29/15)
3rd ................................................................................ 1.437 (23/16)
4th ................................................................................ 1.095 (23/21)
Top ............................................................................... 0.913 (21/23)
Drive chain .......................................................................................... DID 520V, 112 links
CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Link type, coil spring, oil damped
Front fork stroke .................................................................................. 205 mm (8.1 in)
Rear wheel travel ................................................................................ 205 mm (8.1 in)
Caster.................................................................................................. 29
Trail ..................................................................................................... 112 mm (4.4 in)
Steering angle ..................................................................................... 43 (right & left)
Turning radius ..................................................................................... 2.3 m (7.5 ft)
Front brake .......................................................................................... Disc brake
Rear brake........................................................................................... Drum brake
Front tire .............................................................................................. 70/100-21M/C 44P, tube type
Rear tire............................................................................................... 100/90-18M/C 56P, tube type
ELECTRICAL
Ignition type ......................................................................................... Electronic ignition (CDI)
Ignition timing ...................................................................................... 7 B.T.D.C. at 1 500 r/min
Spark plug ........................................................................................... NGK DR8EA or DENSO X24ESR-U
Battery ................................................................................................. 12 V 21.6 kC (6 Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Fuse .................................................................................................... 20 A
Headlight ............................................................................................. 12 V 60/55 W
Brake light/Taillight .............................................................................. 12 V 21/5 W
Turn signal light ................................................................................... 12 V 21 W
Speedometer light ............................................................................... 12 V 1.7 W
Neutral indicator light........................................................................... 12 V 2 W
Turn signal indicator light .................................................................... 12 V 2 W
High beam indicator light..................................................................... 12 V 2 W
CAPACITIES
Fuel tank, including reserve .............................................................. 12.5 L (3.3/2.7 US/Imp gal)
12.0 L (3.2/2.6 US/Imp gal)........ California (U.S.A.)
reserve ............................................................................. 2.5 L (0.7/0.5 US/Imp gal)
Engine oil change ............................................................................. 850 ml (0.9/0.7 US/Imp qt)
with filter change .............................................................. 950 ml (1.0/0.8 US/Imp qt)
overhaul............................................................................ 1 100 ml (1.2/1.0 US/lmp qt)
 99500-41143-01E

PERIODIC MAINTENANCE ATTACHED SHEET: PAGE 3 OF 30

PERIODIC MAINTENANCE CHART

Interval km 1 000 5 000 10 000 15 000
miles 600 3 000 6 000 9 500
Item months 3 15 30 45
Exhaust pipe bolts and muffler bolts T T T
Air cleaner C C C
Valve clearance I I I I
Spark plug I R I
Spark arrester C C C
Fuel hose I I I
(EVAP hose..........California model only) Replace every 4 years
Idle speed (Carburetor) I I I I
Throttle cable play (Carburetor) I I I I
Clutch I I I I
Engine oil R R R R
Engine oil filter R R
I I I I
Drive chain
Clean and lubricate every 1 000 km (600 miles)
Brake I I I I
I I I
Brake hose
Replace every 4 years
I I I
Brake fluid
Replace every 2 years
Tire I I I
Steering I I
Front fork I
Rear suspension I
Chassis bolts and nuts T T T T
NOTE: I = Inspect and adjust, clean, lubricate or replace as necessary, C = Clean, R = Replace, T = Tighten
 99500-41143-01E

PERIODIC MAINTENANCE ATTACHED SHEET: PAGE 4 OF 30

EXHAUST PIPE BOLTS AND MUFFLER BOLTS

Tighten Every 5 000 km (3 000 miles, 15 months).

Remove the right frame cover. (Refer to page 23 of attached

sheet)
Tighten the exhaust pipe bolts, muffler connection bolt and
muffler mounting bolts to the specified torque with a torque
wrench.

A Exhaust pipe bolt 23 N.m

B Muffler connection bolt 2.3 kgf-m
C Muffler mounting bolt (front side) ( 16.5 lbf-ft )
26 N.m
D Muffler mounting bolt (rear side) 2.6 kgf-m
( 19.0 lbf-ft )
 99500-41143-01E

PERIODIC MAINTENANCE ATTACHED SHEET: PAGE 5 OF 30

CHASSIS BOLTS AND NUTS

Tighten Initially at 1 000 km (600 miles, 3 months) and
Every 5 000 km (3 000 miles, 15 months) thereafter.

The nuts and bolts listed below are important safety related parts. They must be retightened when neces-
sary to the specified torque with a torque wrench. (Refer to page 6 of attached sheet for the locations of the
following nuts and bolts on the motorcycle.)

Item Nm kgf-m lbf-ft

1 Steering stem head nut 90 9.0 65.0
2 Front fork upper clamp bolt 30 3.0 21.5
3 Front fork lower clamp bolt 30 3.0 21.5
4 Front axle nut 48 4.8 34.5
5 Handlebar holder nut 45 4.5 32.5
6 Handlebar clamp bolt 23 2.3 16.5
7 Front brake master cylinder mounting bolt 10 1.0 7.0
8 Front brake caliper mounting bolt 26 2.6 19.0
9 Front brake hose union bolt 23 2.3 16.5
0 Air bleeder valve 8 0.8 6.0
A Front brake disc bolt 23 2.3 16.5
B Front footrest bolt 85 8.5 61.5
C Swingarm pivot nut 65 6.5 47.0
D Rear shock absorber nut (Upper & Lower) 60 6.0 43.5
E Rear cushion lever nut 78 7.8 56.5
F Rear cushion lever center nut 72 7.2 52.0
G Rear torque link nut 13 1.3 9.5
H Rear brake cam lever bolt 11 1.1 8.0
I Rear axle nut 65 6.5 47.0
J Seat rail bolt 23 2.3 16.5
 99500-41143-01E

PERIODIC MAINTENANCE ATTACHED SHEET: PAGE 6 OF 30

 99500-41143-01E

ENGINE ATTACHED SHEET: PAGE 7 OF 30

ENGINE REINSTALLATION
EXHAUST SYSTEM COMPONENTS

Exhaust pipe Muffler connection bolt

Exhaust pipe cover Muffler mounting bolt (Front side)
Muffler Muffler mounting bolt (Rear side)
Muffler cover Muffler cover screw
Exhaust pipe bolt Muffler drain plug
Exhaust pipe cover nut *1 Apply muffler seal.

*1

ITEM N.m kgf-m lbf-ft

23 2.3 16.5
5.5 0.55 4.0
23 2.3 16.5
23 2.3 16.5
26 2.6 19.0
3 0.3 2.0
61 6.1 44.0
 99500-41143-01E

CHASSIS ATTACHED SHEET: PAGE 8 OF 30

FRONT WHEEL
FRONT WHEEL COMPONENTS

Front axle
Spacer
Disc
Bearing (LH)
Spacer
Bearing (RH)
Speedometer gear box
Front axle nut
Spoke nipple
Front brake disc bolt

ITEM Nm kgf-m lbf-ft

48 4.8 34.5
4.5 0.45 3.5
D
23 2.3 16.5 FW

REAR WHEEL AND REAR BRAKE

REAR WHEEL COMPONENTS

D
Chain adjuster (LH) FW
Rear sprocket
Bearing (LH)
Spacer
Bearing (RH)
Brake shoe
Brake camshaft
Brake panel
Chain adjuster (RH)
Rear axle
Rear axle nut
Rear sprocket bolt
Spoke nipple
Rear brake cam lever bolt

ITEM N.m kgf-m lbf-ft

65 6.5 47.0
27 2.7 19.5
4.5 0.45 3.5
11 1.1 8.0
 99500-41143-01E

CHASSIS ATTACHED SHEET: PAGE 9 OF 30

STEERING
STEERING COMPONENTS

Steering stem upper bracket

Bearing
Damper
Bearing
Steering stem lower bracket
Handlebar clamp bolt
Steering stem head nut
Front fork upper clamp bolt
Handlebar holder nut
Front fork lower clamp bolt

ITEM N.m kgf-m lbf-ft

23 2.3 16.5
90 9.0 65.0
30 3.0 21.5
45 4.5 32.5
30 3.0 21.5
 99500-41143-01E

ELECTRICAL SYSTEM ATTACHED SHEET: PAGE 10 OF 30

CHARGING SYSTEM
REGULATED VOLTAGE INSPECTION
Remove the frame covers, frame upper covers and seat.
(Refer to page 23 of attached sheet)
Connect the engine tachometer to the high-tension cord.
Start the engine and keep it running at 5 000 r/min with the
dimmer switch turned HI position.
Measure the DC voltage between the + and - battery termi-
nals using the multi circuit tester. If the voltage is not within
the specified value, inspect the generator and regulator/recti-
fier. (Refer to page 11 of attached sheet) Battery
NOTE:
When making this test, be sure that the battery is in fully charged
condition.
DCV
09900-25008: Multi circuit tester set
09900-26006: Engine tachometer
Tester knob indication: Voltage ()
Regulated voltage (Charging output):
13.0 16.0 V at 5 000 r/min

GENERATOR COIL RESISTANCE INSPECTION

Remove the frame covers, frame upper covers and seat.
(Refer to page 23 of attached sheet)
Disconnect the generator coupler 1.
Measure the resistance between the three lead wires.
If the resistance is out of specified value, replace the stator
with a new one. Also, check that the generator core is insu-
lated properly.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance ()
Generator coil resistance: 0.54 0.66 (Y Y) Y
(Y Ground)
Y

Y
 99500-41143-01E

ELECTRICAL SYSTEM ATTACHED SHEET: PAGE 11 OF 30

GENERATOR NO-LOAD PERFORMANCE INSPECTION

Connect the engine tachometer to the high-tension cord.
(Refer to page 10 of attached sheet)
Y
Disconnect the generator coupler. (Refer to page 10 of V
attached sheet) Y V
Start the engine and keep it running at 5 000 r/min. V
Y
Using the multi circuit tester, measure the voltage between
three lead wires.
If the tester reads under the specified value, replace the gen-
erator with a new one.

09900-25008: Multi circuit tester set

Tester knob indication: Voltage (~)
Generator no-load performance:
55 85 V (AC) at 5 000 r/min (When engine is cold)

REGULATOR/RECTIFIER INSPECTION
Remove the frame covers, frame upper covers and seat.
(Refer to page 23 of attached sheet)
Disconnect the regulator/rectifier coupler 1.
Measure the voltage between the terminals using the multi
circuit tester as indicated in the following table. If the voltage
is not within the specified value, replace the regulator/rectifier
with a new one. (Refer to page 26 of attached sheet)

09900-25008: Multi circuit tester set

Tester knob indication: Diode test () B/W
Y1
Unit: V
+ Probe of tester to: Y2
- Probe of tester to:

Y1 Y2 Y3 R B/W
Y1 0.4 0.7
Y2 0.4 0.7 R Y3

Y3 0.4 0.7
R 0.4 0.7 0.4 0.7 0.4 0.7 0.5 1.2
B/W
1.4 V or more (testers battery voltage)
NOTE:
If the tester reads 1.4 V and below when the tester probes are
not connected, replace its battery.
 99500-41143-01E

ELECTRICAL SYSTEM ATTACHED SHEET: PAGE 12 OF 30

IGNITION SYSTEM
IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION
Remove the frame covers, frame upper covers, seat and fuel
tank. (Refer to page 23 of attached sheet)
Disconnect the spark plug cap 1.
Connect a new spark plug to the spark plug cap and ground it
to the cylinder head.

NOTE:
Make sure that the spark plug is connected properly and the bat-
tery is used in fully-charged condition.

Measure the ignition coil primary peak voltage in the following

procedure:
Connect the multi circuit tester with the peak voltage adaptor
as follows.
ignition coil: + Probe: Ground (core)
- Probe: White lead wire terminal
NOTE:
Do not disconnect the ignition coil primary lead wire.
09900-25008: Multi circuit tester set
NOTE:
Before using the multi circuit tester and peak volt adaptor, be Peak volt adaptor
sure to refer to the appropriate instruction manual.
Shift the transmission into neutral, turn the ignition switch
ON and grasp the clutch lever. CDI W
unit
Press the starter switch and allow the engine to crank for a
few seconds, and then measure the ignition coil primary peak New spark plug
voltage.
Repeat the above procedure a several times and measure the
highest ignition coil primary peak voltage.
Tester knob indication: Voltage ()
Ignition coil primary peak voltage: 200 240 V

Do not touch the tester probes and spark plugs to pre-

vent receiving an electric shock while testing.

If the peak voltage is lower than the specified values, inspect the
ignition coil and signal coil. (Refer to page 13, 14 of attached
sheet)
 99500-41143-01E

ELECTRICAL SYSTEM ATTACHED SHEET: PAGE 13 OF 30

IGNITION COIL RESISTANCE INSPECTION

Remove the frame covers, frame upper covers, seat and fuel Terminal
tank. (Refer to page 23 of attached sheet)
Disconnect the ignition coil primary lead wire and plug cap.
(Refer to page 12 of attached sheet)
Measure the ignition coil resistance in both the primary and
secondary coils. If the resistance is not within the standard
range, replace the ignition coil with a new one. Ground

09900-25008: Multi circuit tester set

Tester knob indication: Resistance ()
Ground
Ignition coil resistance
Primary : 0.14 0.18 (Terminal Ground)
Secondary: 15.0 17.4 k (Plug cap Terminal)

Terminal

CDI UNIT INSPECTION

Inspect the ignition system lead wires as shown in the diagram.
Inspect the spark plug, ignition coil and signal coil. (Refer to page 2-5)
(Refer to page 12 to 14 of attached sheet)
If any defects are found, replace or repair the defective part.
If ignition system circuit is OK, replace the CDI unit with a new one.

Ignition switch Engine stop switch

R R O O/Y
R Side-stand relay O/W
Fuse

Regulator/
Battery rectifier
Ignition coil

CDI unit W
Y Y Y G Spark
B/R plug
B/W
Signal coil
Generator
B/W
 99500-41143-01E

ELECTRICAL SYSTEM ATTACHED SHEET: PAGE 14 OF 30

SIGNAL COIL PEAK VOLTAGE INSPECTION

NOTE:
Be sure that all couplers are connected properly and the battery
used is in fully-charged condition.
Remove the frame covers, frame upper covers and seat.
(Refer to page 23 of attached sheet)
Disconnect the signal coil coupler 1 and connect the multi
circuit tester with the peak volt adaptor as follows.
B/R lead wire (+ Probe) G lead wire (- Probe)
09900-25008: Multi circuit tester set
NOTE:
Before using the multi circuit tester and peak volt adaptor, be
sure to refer to the appropriate instruction manual.

Measure the signal coil peak voltage at the signal coil coupler.
Shift the transmission into neutral, turn the ignition switch ON Signal coil
Peak volt
coupler
and grasp the clutch lever. adaptor
B/R
Press the starter switch and allow the engine to crank for a G
few seconds, and then measure the signal coil peak voltage. Signal
coil
Repeat the above test procedure a several times and mea-
sure the highest peak voltage.
Tester knob indication: Voltage ()
Signal coil peak voltage: 4.5 V or more (+ B/R - G)
If the peak voltage is within the specification, check the continu-
ity between the signal coil coupler and CDI unit coupler.

SIGNAL COIL RESISTANCE INSPECTION

Signal coil
Disconnect the signal coil coupler.
coupler
Measure the resistance between the lead wires and ground. If
B/R
the resistance is not within the standard range, replace the G
signal coil with a new one. Signal
coil
09900-25008: Multi circuit tester set
Tester knob indication: Resistance ()
Signal coil resistance: 148 222 (B/R G)
(G Ground)
 99500-41143-01E

ELECTRICAL SYSTEM ATTACHED SHEET: PAGE 15 OF 30

SPEEDOMETER AND INDICATOR LIGHT

REMOVAL AND DISASSEMBLY
Remove the speedometer and indicator light as follows.
Disassemble the speedometer and indicator light as follows.

Pilot light box

Pilot light box

2 N.m
0.2 kgf-m
( 1.5 lbf-ft )
Speedometer

Speedometer

Bulb
2 N.m
10 N.m
0.2 kgf-m
( 1.0 kgf-m
)
7.0 lbf-ft
( 1.5 lbf-ft )
2 N.m
0.2 kgf-m
( 1.5 lbf-ft )
5 N.m
0.5 kgf-m
Bulb ( )
3.5 lbf-ft
10 N.m
1.0 kgf-m
( 7.0 lbf-ft)
45
2.5 N.m
0.25 kgf-m
( 2.0 lbf-ft )

INSPECTION
Check the continuity between lead wires using the multi circuit
HI NU TU
tester. If there is no continuity replace the respective parts.
09900-25008: Multi circuit tester
SP
Tester knob indication: Continuity test ()

NOTE:
B/Lg
B/Bl
B/W

B/W
B/O
B/R
Gr

When making this test, it is not necessary to remove the speed-

ometer.

SP: Speedometer light

HI: High beam indicator light
NU: Neutral indicator light
TU: Turn signal indicator light
 HANDLEBAR SWITCH (RH)
HI: HIGH BEAM INDICATOR LIGHT ENGINE STOP STARTER FRONT BRAKE
NU: NEUTRAL INDICATOR LIGHT PILOT LIGHT SPEEDOMETER SWITCH SWITCH LIGHT SWITCH
OFF OFF
SIDE-STAND SWITCH
TU: TURN SIGNAL INDICATOR LIGHT HI NU TU REAR BRAKE LIGHT
RUN PUSH ON
SP SWITCH PUSH
CDI UNIT ON TURN SIGNAL FREE
IGNITION COIL OFF
SIDE-STAND RELAY
SIDE-STAND RELAY
DIODE

B
O

O
O

B/R
B/O
Gr

B/W
B/Bl
B/Lg
O/Y
Y/G
W/B
G

Y/W

B/W
O/W
B/W

O
O/Y
Y/G
Y/W

Gr
W/B
O/W

Y
O
O

O
O
O

B/W
G

Lg
W
W

Bl
O/Y

Lbl
B/W
G/W
G/W

B/W
Bl/B
B/R
W/B

B/W
B/W

G/W
Bl/B
O/W
WIRING DIAGRAM

REAR TURN
FRONT TURN SIGNAL LIGHT (RH) SIGNAL LIGHT (RH)
Lg Lg Lg Lg
B/W B/W B/W B/W
SERVICING INFORMATION

HEADLIGHT REAR COMBINATION LIGHT

Y Br Br
B/W B/W B/W
W W/B W/B

B B B B
B/W B/W B/W B/W

FRONT TURN SIGNAL LIGHT (LH) REAR TURN

SIGNAL LIGHT (LH)

Y/G
B/W
B/W

R
R
R
R

G
O
O

Y
B

G
Bl
Y
Y
Y

Lg
G
Y
Y
Y
R

Lbl
Y/G
Y/G

Y/W
B/W
B/R
B/W
99500-41143-01E

Y/G
B/W

Y
Y
Y

R
O
Bl

Y
B/R

Lg
12V

Lbl
Y/G
Y/G

Y/W
B/W
B/Bl
HORN OFF OFF
OFF ON ON BATTERY
ON
STARTER RELAY FUSE BOX
REGULATOR/RECTIFIER
IGNITION SWITCH (20A)
CLUTCH LEVER M STARTER MOTOR
POSITION SWITCH NEUTRAL SWITCH
HI L
LO PUSH PUSH
GENERATOR
R
DIMMER HORN
SWITCH SWITCH TURN SIGNAL
LIGHT SWITCH
WIRE COLOR
HANDLEBAR SWITCH (LH)
B : Black Lg : Light green B/Bl : Black with Blue tracer G/W : Green with White tracer
Bl : Blue O : Orange B/Lg : Black with Light green tracer O/W : Orange with White tracer
Br : Brown R : Red B/O : Black with Orange tracer O/Y : Orange with Yellow tracer
G : Green W : White B/R : Black with Red tracer W/B : White with Black tracer
Gr : Gray Y : Yellow B/W : Black with White tracer Y/G : Yellow with Green tracer
Lbl : Light blue Bl/B : Blue with Black tracer Y/W : Yellow with White tracer
ATTACHED SHEET: PAGE 16 OF 30
 99500-41143-01E

SERVICING INFORMATION ATTACHED SHEET: PAGE 17 OF 30

WIRING HARNESS ROUTING

Bind the clamp behind the branch wire. Face the tip of clamp to inside.
Clamp Do not slacken the wiring harness and
Face the tip of clamp to inside. Pass the starter motor
rear combination light lead wire.
Clamp Wiring harness lead wire outside of the
Starter motor
Wiring harness CDI unit installation part.
lead wire Wiring harness Starter motor
Pass the starter Rear combination light Cut off the excess tip of the clamp.
Starter motor
motor lead wire Clamp
Mud flap under the frame Do not pull the rear
Air cleaner
bridge. combination light lead Wiring harness
Do not pinch the wiring wire with the seat bracket.
harness with the seat. Rear combination light

Do not slacken the

wiring harness.

Put the generator coupler, neutral switch

Pass the side-stand switch lead wire
coupler and battery ground wire coupler
between the bosses of the rear fender.
between the frame and air cleaner. Battery terminal CDI unit Regulator/rectifier
Do not pinch the couplers with the seat. coupler and
Starter motor Starter Starter motor
Face the tip of clamp to left or right side. relay terminal motor relay relay coupler
Clamp Pass the starter motor Face the tip of clamp to inside.
lead wire between the Face the tip of Clamp
Starter motor
engine mounting brackets. clamp to inside.
Wiring harness (Blue tape)
Generator lead wire and Mud flap
Neutral switch lead wire
Air cleaner

Starter motor
Pass the starter motor
lead wire
lead wire behind the
tank brace.
Pass the battery lead wire
Pass the starter motor outside of the regulator/rectifier.
lead wire left side of the 100 mm
cable clamp. (3.9 in) Pass the battery lead wire from the space of frame.
Do not pinch the lead wire with frame cover.
80 mm
(3.1 in)
Set the branch wire in front of the bracket and
Generator bind the clamp in front of the branch wire.
Neutral switch Face the lock part of clamp to left side and tip
Battery of clamp downward.
Side-stand switch Clamp
Clamp Wiring harness
Clamp
Face the tip of clamp to inside. Throttle cable
Wiring harness Do not slacken the
wiring harness.
Face the tip of clamp to inside. Clamp
Starter motor
lead wire Clamp
Wiring harness
Wiring harness
Clutch cable
Starter motor

Battery holder
Bind the clamp over the clutch cable clamp.
Turn signal relay Face the lock part of clamp forward and tip
of clamp to left side.
Clamp
Side-stand relay Starter motor
Clutch cable

Wiring harness
Clutch cable
Insert the fuse to Clamp
the rear fender. Rear brake
light switch
Starter motor 90 or less
Pass the fuse lead wire in Do not contact the clamp
front of the frame. Clamp terminal
to the engine mounting nut.
Face the tip of clamp to inside.
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SERVICING INFORMATION ATTACHED SHEET: PAGE 18 OF 30

Pass the pilot light lead wire, ignition switch lead wire, handlebar switch lead wire (RH)
Clamp and turn signal light lead wire (RH) under the throttle cable.
Handlebar switch (RH) Pass the clutch lever position switch lead wire and handlebar switch lead wire (LH) in front of the throttle cable.
30 50 mm Pass the speedometer light lead wire and turn signal light lead wire (LH) behind the throttle cable.
(1.2 2.0 in)
Clamp
Handlebar switch (LH)
Throttle cable Clutch lever position switch

Clutch cable
Pass the clutch lever position switch lead wire, handlebar switch lead wire (LH)
and turn signal light lead wire (LH) behind the clutch cable.
Handlebar switch (RH & LH) Wrap the cover to the lead wires
Pilot light after connecting the couplers.
Do not wrap the bracket.
Speedometer light
Clutch lever position switch
Front turn signal light (RH & LH) Clamp
Ignition switch Front turn signal light (LH)
Wiring harness (Blue tape)
2.5 N.m
Clamp
(0.25 kgf-m, 1.8 lbf-ft)
Face the tip of
clamp to inside.

Throttle cable
Clutch cable
10 N.m
(1.0 kgf-m, 7.0 lbf-ft)

Pass the wiring harness Wiring harness

in front of the
speedometer cable.
Pass the wiring harness
between the throttle
cable and clutch cable.
45 10
Speedometer cable

90 10

Neutral switch
Battery ground wire 4.5 N.m
(0.45 kgf-m, 3.5 lbf-ft)
Generator lead wire

45 10

45 10

45
Retainer
10 4.5 N.m
80 N.m (0.45 kgf-m, 3.5 lbf-ft)
(8.0 kgf-m, 58.0 lbf-ft)
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SERVICING INFORMATION ATTACHED SHEET: PAGE 19 OF 30

THROTTLE CABLE AND CLUTCH CABLE ROUTING

Clamp the throttle cable

Pass the clutch lever position switch lead and brake hose union. Front brake hose
wire, handlebar switch lead wire (LH) and
turn signal light lead wire (LH) behind Throttle cable clamp
Throttle cable
the clutch cable. Clutch cable

Clutch cable

Front brake hose

Throttle cable
Pass the clutch lever position switch lead wire,
handlebar switch lead wire (LH),
speedometer light lead wire and
turn signal light lead wire (LH)
behind the throttle cable.

Clutch cable

5 10 mm
Pass the throttle cable in front of the (0.2 0.4 in)
Throttle cable
clutch cable within the cable guide.

4.5 N.m
(0.45 kgf-m, 3.5 lbf-ft)

Throttle cable
Clamp
Clamp
Clutch cable
Clamp
Wiring harness

FWD

Clamp 45 Clutch cable

60 mm
(2.4 in) Clutch cable

Clamp

Wiring harness
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SERVICING INFORMATION ATTACHED SHEET: PAGE 20 OF 30

SPEEDOMETER CABLE ROUTING

5 N.m
(0.5 kgf-m, 3.5 lbf-ft)
Clutch cable Pass the cable into the guide.
Install the Frame head
speedometer pipe
cable securely.
Align the clamp hole with
Pass the speedometer cable between projection of front fork.
the clutch cable and frame head pipe.
Speedometer
cable

Do not bend the

speedometer cable
within 100 mm
(3.9 in) of radius.
Tighten the screw after installing
Do not slacken the the speedometer cable securely. Pass the cable into the clamp.
speedometer cable.
10 N.m
(1.0 kgf-m, 7.0 lbf-ft)
Parallel the speedometer cable with Speedometer gear box
the convex part of front fork. 0

FUEL HOSE ROUTING

Match mark
Face the clamp
end downward.

Fuel valve Vacuum hose

Fuel valve

Vacuum hose
Carburetor Fuel hose

Face the clamp end backward.

Gasket

4.4 N.m
(0.44 kgf-m, 3.0 lbf-ft)
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SERVICING INFORMATION ATTACHED SHEET: PAGE 21 OF 30

EVAP CANISTER HOSE ROUTING (If equipped)

Regulator/rectifier coupler and

Starter motor relay coupler
Clamp
Starter motor Canister
air hose
Hose (Tank & Valve)

Spring
Canister air hose

Wiring harness Clamp

Face the tip of clamp to inside.

Clamp
Canister air hose
Face the clamp
end upward.

Set the spring end at 0 40 mm

Fuel valve (0 1.6 in) from the clamp.
Fuel hose
Hose (Tank & Valve)
Face the tip of
Face the clamp Canister clamp backward.
end backward. band
To carburetor Canister plate
EVAP canister Frame

Face the clamp Clamp Canister air

end to left side. hose
Wiring harness

vacuum hose
Face the clamp end
Fuel shut-off valve to right side.

Spring
Spring
Hose (Valve & Canister)
Purge hose
Face the tip of clamp
to inside.

Face the clamp end backward.

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SERVICING INFORMATION ATTACHED SHEET: PAGE 22 OF 30

FRONT BRAKE HOSE ROUTING

Pass the brake hose in front

of the throttle cable.
47 23

Throttle cable

After the brake hose union

Washer has contacted the stopper, After the stopper of brake hose
tighten the union bolt. upper guide has contacted the
turn signal bracket, tighten the
Turn signal bracket (LH) clamp bolt.

Clutch cable

Set the brake hose upper guide

outside of the turn signal bracket.
Pass the brake hose in front
of the clutch cable.

Brake hose clamp

Brake hose upper guide

Brake hose lower guide

Face the black paint to

caliper body side.

After the brake hose

union has contacted
the stopper, tighten
the union bolt.

Washer
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SERVICING INFORMATION ATTACHED SHEET: PAGE 23 OF 30

EXTERIOR PARTS CONSTRUCTION

Seat
Frame center cover
Frame upper cover
Frame inner cover
Frame cover
Rear fender (rear)
Rear fender (front)
Fuel tank
Fuel tank cover
Fuel tank cover brace
Headlight cover
Front fender

5.5 N.m
(0.55 kgf-m, 4.0 lbf-ft)

D
FW
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SERVICING INFORMATION ATTACHED SHEET: PAGE 24 OF 30

HANDLEBARS INSTALLATION

Apply handle grip bond.

1 N.m
(0.1 kgf-m, 0.5 lbf-ft)

10 N.m 23 N.m
(1.0 kgf-m, 7.0 lbf-ft) 10 N.m
(2.3 kgf-m, 16.5 lbf-ft)
(1.0 kgf-m, 7.0 lbf-ft)

Clearance
Clearance

Align the clutch lever holders

Align the master cylinders mating surface mating surface with the punch
with the punch mark on the handlebars Align the left handlebar holders mating mark on the handlebars and
and tighten the upper bolt first. surface with the punch mark on the tighten the upper bolt first.
handlebars and tighten the clamp bolts
6 N.m 6.5 N.m
to equalize the clearances .
(0.6 kgf-m, 4.5 lbf-ft) (0.65 kgf-m, 4.5 lbf-ft)
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SERVICING INFORMATION ATTACHED SHEET: PAGE 25 OF 30

FRONT FOOTREST INSTALLATION

85 N.m
(8.5 kgf-m, 61.5 lbf-ft)
Do not reuse.
Do not reuse.
Cotter pin

Front
footrest (RH)

Pin

Spring

85 N.m
(8.5 kgf-m, 61.5 lbf-ft)
Do not reuse.
Pin

Spring

Front footrest (LH)

SEAT RAIL INSTALLATION

Seat rail
Rear frame plate (RH)
23 N.m Cushion
(2.3 kgf-m, 16.5 lbf-ft)

Rear frame plate (LH)

23 N.m
(2.3 kgf-m, 16.5 lbf-ft)

Frame
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SERVICING INFORMATION ATTACHED SHEET: PAGE 26 OF 30

ELECTRICAL PARTS INSTALLATION

Contact the CDI unit to the front wall.

4.5 N.m
(0.45 kgf-m, 3.5 lbf-ft)

Band
CDI unit

Ignition coil

Rear front fender

Clamp the protective tube.

Regulator/rectifier
5.5 N.m
(0.55 kgf-m, 4.0 lbf-ft)
9 N.m
(0.9 kgf-m, 6.5 lbf-ft) Battery holder

90

Starter motor relay

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SERVICING INFORMATION ATTACHED SHEET: PAGE 27 OF 30

TIGHTENING TORQUE
ENGINE
ITEM Nm kgf-m lbf-ft
Cylinder head cover bolt 10 1.0 7.0
Camshaft sprocket bolt 11 1.1 8.0
Cylinder head nut M8 27 2.7 19.5
Cylinder head nut M6 10 1.0 7.0
Cylinder base nut 10 1.0 7.0
Starter clutch securing bolt 25 2.5 18.0
Cam drive chain tension adjuster bolt 7 0.7 5.0
Generator rotor nut 90 9.0 65.0
Crankcase bolt 11 1.1 8.0
Primary drive gear nut 50 5.0 36.0
Clutch cover bolt and generator cover bolt 10 1.0 7.0
Starter motor lead wire connecting bolt 2.5 0.25 1.8
Starter motor mounting bolt 10 1.0 7.0
Starter motor relay mounting screw 5.5 0.55 4.0
Clutch sleeve hub nut 50 5.0 36.0
Gearshift arm stopper 19 1.9 13.5
Engine oil drain plug 28 2.8 20.0
Oil filter cap nut and oil pump filter cap bolt 7 0.7 5.0
Engine sprocket bolt 25 2.5 18.0
Engine mounting bolt (Top side) 41 4.1 29.5
Engine mounting bolt (Front side) 88 8.8 63.5
Engine mounting bolt (Rear side) 10 1.0 7.0
Engine mounting bracket bolt 41 4.1 29.5
Exhaust pipe bolt 23 2.3 16.5
Muffler connection bolt 23 2.3 16.5
Muffler mounting bolt (Front side) 23 2.3 16.5
Muffler mounting bolt (Rear side) 26 2.6 19.0
Exhaust pipe cover nut 5.5 0.55 4.0
Muffler cover screw 3 0.3 2.0
Muffler drain plug 61 6.1 44.0
Stator coil bolt 4.5 0.45 3.5
Signal coil bolt 4.5 0.45 3.5
Throttle cable lock nut (Carburetor side) 4.5 0.45 3.5
Ignition coil mounting screw 4.5 0.45 3.5
Regulator/rectifier mounting bolt 9 0.9 6.5
Fuel valve mounting bolt 4.4 0.44 3.0
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SERVICING INFORMATION ATTACHED SHEET: PAGE 28 OF 30

CHASSIS
ITEM Nm kgf-m lbf-ft
Front axle nut 48 4.8 34.5
Front fork damper rod bolt 20 2.0 14.5
Front fork lower clamp bolt 30 3.0 21.5
Front fork upper clamp bolt 30 3.0 21.5
Steering stem head nut 90 9.0 65.0
Handlebar clamp bolt 23 2.3 16.5
Handlebar holder nut 45 4.5 32.5
Front brake master cylinder mounting bolt 10 1.0 7.0
Front brake lever pivot bolt 1 0.1 0.5
Front brake lever pivot bolt lock nut 6 0.6 4.5
Front brake caliper mounting bolt 26 2.6 19.0
Front brake pad mounting bolt 18 1.8 13.0
Front brake caliper axle bolt 23 2.3 16.5
Front brake hose union bolt 23 2.3 16.5
Air bleeder valve 8 0.8 6.0
Front brake disc bolt 23 2.3 16.5
Swingarm pivot nut 65 6.5 47.0
Front footrest bolt 85 8.5 61.5
Rear torque link nut 13 1.3 9.5
Rear shock absorber nut (Upper & lower) 60 6.0 43.5
Rear cushion lever center nut 72 7.2 52.0
Rear cushion lever nut 78 7.8 56.5
Rear axle nut 65 6.5 47.0
Rear sprocket bolt 27 2.7 19.5
Rear brake cam lever bolt 11 1.1 8.0
Rear brake pedal nut 13 1.3 9.5
Spoke nipple 4.5 0.45 3.5
Seat rail bolt 23 2.3 16.5
Clutch lever holder bolt 10 1.0 7.0
Clutch lever pivot bolt lock nut 6.5 0.65 4.5
Headlight cover screw 5.5 0.55 4.0
Speedometer mounting nut 2.5 0.25 2.0
Speedometer bracket mounting bolt 10 1.0 7.0
Pilot light box mounting screw 2 0.2 1.5
Pilot light box holder mounting screw 2 0.2 1.5
Speedometer cable nut 5 0.5 3.5
Speedometer cable screw 10 1.0 7.0
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SERVICING INFORMATION ATTACHED SHEET: PAGE 29 OF 30

SERVICE DATA
CARBURETOR
SPECIFICATION
ITEM
For others For California (U.S.A.)
Carburetor type MIKUNI BST31SS
Bore size 31 mm
I.D. No. 42AC 42AE
Idle r/min 1 500 100 r/min
Float height 13.0 1.0 mm (0.51 0.04 in)
Main jet (M.J.) #
Jet needle (J.N.) 5D77
Needle jet (N.J.)
Throttle valve (Th.V.) #125
Pilot jet (P.J.) #
Starter jet (G.S.) #25
Pilot screw (P.S.) PRE-SET
Throttle cable play 2 4 mm (0.08 0.16 in)

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Spark plug Type DENSO: X24ESR-U
NGK: DR8EA
Gap 0.6 0.7
(0.024 0.028)
Spark performance Over 8 mm (0.3) at 1 atm.
Signal coil resistance 148 222 B/R G
Signal coil peak voltage 4.5 V or more + B/R - G
Ignition coil resistance Primary 0.14 0.18 Terminal
Ground (core)
Secondary 15.0 17.4 k Plug cap
Terminal
Ignition coil primary peak voltage 200 240 V + Ground (core)
-W
Generator coil resistance 0.54 0.66
Generator no-load voltage 55 85 V (AC) at 5 000 r/min
(When engine is cold)
Generator Max. output 150 W at 5 000 r/min
Regulated voltage 13.0 16.0 V at 5 000 r/min
Starter relay resistance 26
Battery Type designation YTX7L-BS
Capacity 12 V 21.6 kC (6 Ah)/10 HR
Fuse size 20 A
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SERVICING INFORMATION ATTACHED SHEET: PAGE 30 OF 30

WATTAGE Unit: W
ITEM SPECIFICATION
Headlight HI 60
LO 55
Brake light/Taillight 21/5
Turn signal light 21
Speedometer light 1.7
Turn signal indicator light 2
High beam indicator light 2
Neutral indicator light 2

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use unleaded gasoline with an octane rating of 87
AKI or higher.
Do not use leaded gasoline.
Unleaded gasoline containing up to 15% MTBE by
volume may be used. For U.S.A. and
Unleaded gasoline containing up to 10% ethanol by Canada
volume may be used.
Unleaded gasoline containing up to 5% methanol
by volume may be used if it also contains appropri-
ate cosolvents and corrosion inhibitors.
Use unleaded gasoline with an octane rating of 91
RON or higher.
Do not use leaded gasoline.
Fuel tank capacity including 12.5 L
reserve (3.3/2.7 US/lmp qt)
12.0 L For California
(3.2/2.6 US/lmp qt) (U.S.A.)
reserve 2.5 L
(0.7/0.5 US/lmp qt)
Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity Change 850 ml
(0.9/0.7 US/lmp qt)
Filter change 950 ml
(1.0/0.8 US/lmp qt)
Overhaul 1 100 ml
(1.2/1.0 US/lmp qt)
Front fork oil type Fork oil #10
Front fork oil capacity (each leg) 309 ml
(10.4/10.9 US/lmp oz)
Brake fluid type DOT 4