Kove 450 RALLY 2022 User manual

450 Rally Maintenance manuals
First Edition (February 2023)
This maintenance manual is copyrighted by TIBET NEW
SUMMIT MOTORCYCLE CO.,LTD.
The contents and pictures of this maintenance manual are for
reference only, please refer to the actual.
English
version
1

Introduction
This motorcycle manual provides the reader with a detailed introduction to the basic
structure, operating principles, disassembly and overhaul, and troubleshooting methods
of the 450 Rally motorcycle. It also introduces the technical specifications, performance
parameters and maintenance adjustment data of this model. It is hoped that this manual
will provide technical support and guidance to the users and after-sales service personnel
of Kaiyue motorcycles.
The technical specifications, performance parameters and maintenance adjustment
data indicated in this manual are based on the latest status. Please note that any
subsequent improvements made by the Company to this model may not be in
accordance with this manual without prior notice. We sincerely hope that you will give us
your valuable opinions and suggestions on the design, manufacture and quality of this
model, and inform us for timely improvement.
All the information, charts and various data and performance indexes published in
this manual are available until the printing of this manual. Please understand that TIBET
NEW SUMMIT MOORCYCLE CO.,LTD., reserves the right to make changes to this manual
without prior notice. Any part of this manual is the copyright of TIBET NEW SUMMIT
MOTORCYCLE CO.,LTD. Otherwise, they will be held criminally and legally responsible.
Due to the limited level of the editor, there are inevitably errors and omissions in this
manual, so please criticize and correct
TIBET NEW SUMMIT MOORCYCLE CO.,LTD.
Address: No. 2, Xiangyu Road, Shuangfengqiao Street, Yubei District, Chongqing
Customer service hotline :[phone]
For more information, please visit our website at www.colovemotor.com
2
English
version

Contents
Introduction
Chapter 1 Overview ....................................................................................................... 1
Chapter 2 Basic information ....................................................................................... 3
Chapter 3 Regular maintenance and adjustment .............................................. 28
Chapter 4 Frame, body trim, exhaust system ...................................................... 72
Chapter 5 EFI ................................................................................................................... 89
Chapter 6 Fuel System .............................................................................................. 124
Chapter 7 Cooling System ........................................................................................ 139
Chapter 8 Engine ......................................................................................................... 150
Chapter 9 Cylinder head assy ................................................................................ 158
Chapter 10 Cylinder block and piston ................................................................. 169
Chapter 11 Clutch, driving gear, overrunning clutch, oil pump, gearshift
mechanism ..................................................................................................................... 175
Chapter 12 Magneto and balance driving and driven gear ......................... 187
Chapter 13 Crankcase, crankshaft, variable speed drive, balance shaft ... 193
Chapter 14 Front wheels, suspension, steering ................................................. 199
Chapter 15 Rear wheel, suspension........................................................................ 216
Chapter 16 Hydraulic brake system ....................................................................... 223
Chapter 17 ABS ............................................................................................................. 234
Chapter 18 Electrical parts ........................................................................................ 249
Chapter 19 Circuit schematic diagram ( factory ediion)..................................272
Chapter 20 Circuit schematic diagram (regular edition)..................................273
3
English
version

How to use this manual
This manual describes the maintenance procedures for the 450 Rally.
Chapter 2 and 3 apply to the entire motorcycle. Chapter 4 describes the procedures for removing/installing
components that may be used to perform the services described in the following sections. Chapter 3--
Chapter 19 describe the motorcycle's components, grouped by location. If you are not familiar with this
motorcycle, please read the technical characteristics in Chapter 2. Follow the recommendations of the
maintenance schedule (Chapter 3) to ensure that the motorcycle is in optimum operating condition and that
emission levels meet domestic environmental requirements, then go to the table of contents on the first
page of that section. Most sections begin with program sets or system descriptions, maintenance
information and troubleshooting. Detailed procedures are given on the next few pages. Refer to each section
for troubleshooting based on the fault or symptom.
Your safety and the safety of others is very important. To help you make informed decisions, we have
provided safety information and other information in this manual .
You must use your own good judgment. You will find important safety information in various forms,
including.
Chapter 1
1
*Safety labels
*Safety Message - Precede the safety warning symbol with one of three signal words,
i.e., DANGER, WARNING, or CAUTION. The meaning of these signal words is:
If you do not follow the instructions, death or serious injury will result.
Failure to follow instructions may result in death or serious injury.
If you do not follow instructions, you may be injured.
Instructions - How to properly and safely service this vehicle
English
version

Symbol
The symbols used in this manual represent specific repair procedures. If additional information
related to these symbols is required, it will be explained in detail in the text without using these
symbols
Replace parts with new parts before assembly
Use recommended oils unless otherwise explanation
Use molybdenum oil solution (oil and molybdenum grease
mixed in a ratio of 1:1)
Use multi
-purpose high temperature extreme pressure
compound lithium base grease (Youlicheng Grease SU
-
T330G/F or equivalent grease)
Molybdenum disulfide grease
Use molybdenum disulfide paste (40% or more
molybdenum disulfide, NLGI #2 or equivalent).
For example: G
-n paste made by Dow Corning USA
Honda Moly 60 (USA only). Rocol paste from Sumico
Lubricants, Japan, manufactured by Rocol Ltd.
Use of silicone grease
Apply sealant. Use a medium strength sealant unless
otherwise specified
Application of sealants
Use DOT4 brake fluid. Use recommended brake fluid unless
otherwise stated
Use shock absorbing fluid
2
English
version

Basic information
1 Maintenance rules ................................................................................................. 4
2 Model identification .............................................................................................. 5
3 Basic information ................................................................................................... 6
4 Torque value - engine part ............................................................................... 13
5 Torque value - body part .................................................................................. 15
6 Lubrication and sealing point - Engine part................................................ 26
7 Lubrication and sealing point - body part................................................... 27
3
English
version

Maintenance rules
1. Please use genuine or KOVE recommended parts and lubricants or their
equivalents for the KUVE. Parts that do not meet KOVE's design
specifications may damage the motorcycle.
2. Use special tools designed for this product to avoid damage and
incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts
and bolts are not interchangeable with imperial fasteners.
4. Use new gaskets, O-rings, cotter pins and locking plates when
reassembling.
5. When tightening bolts or nuts, start with large diameter or inner bolts.
Then tighten in diagonal increments to the specified torque, unless a
specific sequence is specified.
6. Clean parts with cleaner when disassembling. Lubricate all sliding surfaces
before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all wires as shown in the cable and cableway wiring.
9. Do not bend or twist control cables. Damaged control cables will not
work properly and may become stuck or tangled.
10.Abbreviations
Throughout this manual, the following abbreviations are used to identify
the respective components or systems.
Abbreviation Full Name
ABS
Anti
-lock braking system (450Rally factory version
without ABS)
CKP
sensor
crankshaft position sensor
DLC
Data link connector
DTC
Direct Torque Control
ECU
Engine control
unit
ECT
sensor
Engine coolant temperature sensor
EEP
ROM
Electrically Erasable Programmable Read
-
Only Memory
EOP
switch
Engine oil pressure switch
EVAP
Evaporative Emission Control System
IAT
sensor
intake air temperature sensor
MAP
sensor
ManifoldAbsolutePressureSensor
MCS
Motorcycle communication system
MIL
Malfunction Indicator Lamp
O
2sensor
oxygen sensor
SCS Service
connector
Service
connector
TP sensor
throttle position sensor
VS sensor
vehicle speed sensor
4
English
version

Model identification
factory edition-⑴regular edition-⑵
⑴
⑵
5
English
version

Basic information
items specification
Size
Total lenght
2190 mm
Total Width
830 mm
Total height
1487 mm
Axle distance
1475 mm
Load free seat height
960 mm
No load pedal height
360 mm
No load ground clearance
300 mm
Dry weight
155 kg
Permissible maximum front axle load
150 kg
Permissible maximum load on rear axle
210 kg
Permissible maximum weight
150 kg
Frame
Frame type
Cradle type frame
Front Suspension
Inverted telescopic fork
Front
shock absorber stroke
305 mm
Rear Suspension
External spring hydraulic
Rear shock absorber stroke
117 mm
Front tire size
90/90
-21M/C
Rear tyre size
140/80
-18M/C
Front tyre brand
Zhengxin
Rear
tyre brand
Zhengxin
Front Brake
Hydraulic single disc 298mm
Rear
Brake Hydraulic single disc 240mm
Caster angle
28
°
Towing distance
122 mm
Fuel tank capacity
31L
Engine
Cylinder alignment
1 cylinder inline, 18°
vertical
tilt
Cylinder diameter and stroke
94.5x64mm
Displacement
499cm
3
Compression ratio
12.5:1
Air distribution system
Double overhead camshaft
four-valve chain drive
intake
valve
-
5°BTDC
-
5°BTDC
35
°ABDC
35
°ABDC
exhaust
valve
33
°BBDC
33
°BBDC
-
13°ATDC
-
13°ATDC
lubricating system
Forced pressure lubrication +
splash lubrication
Oil pump type
Oscillating type
Cooling system
water cooling
Air filltration
Paper cartridge，oil-based
sponge
Engine dry weight
37kg
Ignition sequence
/
Number of cylinder
single cylinder
6
English
version

items specification
The Fuel
Supply
System
Type
Bosch EFI
Throttle valve hole
46mm
Drive system
Clutch system
Wet multichip type
Clutch operating
system
Cable operation
Gearbox
Normal mesh two
-stage
transmission, 6
-speed
Primary drive
2.286
（69/34）
Final drive
3.769
Gear Ratio
1th
2.357
（43/15）
2th
1.824 (46/14)
3th
1.474 (40/19)
4th
1.181(32/20)
5th
1.000(26/20)
6th
0.846(23/20)
Gear Shift Mode
international
1-N-2-3-4-5-6
Electricity
Ignition system
electron ignition
Starting system
electric starter
Charging system
Three-phase output magnetic motor
Regulator/rectifier
Three
-phase full-wave rectification
Lighting System
Battery
items specification
Engine idle
1600
±100rpm
ECT Sensor resistance
（40°C/104°F
）
1.0
-1.2kΩ
IAT
Sensor resistance（20°C/68°F
）
2
-4kΩ
Fuel injector resistance
（20°C/68°F
）
11
-13Ω
Oxygen sensor heater resistance
（
20
°C/68°F）
10
-40Ω
Idle motor resistance
（25°C/77°F
）
110
-150Ω
items specification
Sparking plug
CR8E
（NGK）
Spark Plug Clearance
0.80
-0.90
Spark plug resistance
5
-8 KΩ
items Standard value limit value
Start motor brush
length
12.0-13.0（0.47-0.51）
6.5
（0.26）
EFI specification Measurement units：mm
Ignition system specification Measurement units：mm
Electric starter specifications Measurement units：mm
7
English
version

Start motor brush length
cooling system
items specification
Cooling capacity
radiator tank
1.2 L
The radiator cap releases pressure
108
-133 kPa
Thermostat
Start turning on the
temperature
82
±2℃
Fully open temperature
92
°C
valve lift
Not less than 8 mm
Recommended Antifreeze
Alcohol-free silicate coolant
(Dongfeng Castrol LEC-II-25)）
Standard coolant concentration
1:1 mixture with distilled water
Lubrication system specification
items Standard value
limit value
engine
oil
capacity
After oil change
1.4 L -
After changing
the oil filter
1.6 L -
After removing
the engine
1.8 L
Recommended engine oil
Recommended SG10W
-
50API service
classification:SG or higher
(except for oils marked as
energy efficient on the
round API service
label)JASO T903
standard:MA viscosity:SAE
10W
-50
-
items specification
hrottle body identification number
450R
Fuel pressure at idle
3
80Kpa±10kpa
Fuel pump flow (12V, 380kpa)
≥
30L/h
F
uel oil supply system
Type
Bosch EFI
/
Throttle valve hole
46
mm
8
English
version

9
items
Standard value
limit value
valve
Outside diameter
of valve stem
Intake
φ5.472
-
φ5.487
φ5.46
Exhaust
φ5.46-φ5.475 φ5.44
Valve tube
diameter
Intake
φ5.505
-
φ5.515
φ5.535
Exhaust
φ5.505
-
φ5.515
φ5.535
Valve stem and
tube clearance
Intake 0.018-0.043 0.07
Exhaust
0.03-0.055 0.08
Valve seal tape width
1.2 ----
Cylinder
Head
Planeness
0.05 0.06
Width of valve seat working surface 0.8 ----
items Standard value limit value
Valve spring free length outer:47.5 inner:38.1
outer
:47.35 inner
:37.95
valve clearance
Intake:
0.1-0.15
Exhaust:
0.15-0.2
Intake
＞0.17
Exhaust
＞0.22
Camshaft base circle run-
out 0.02 0.04
items Standard value limit value
cylinder
cylinder bore φ94.5-φ94.52 φ94.528
Out of roundness 0.05 0.01
Flatness of cylinder
surface 0.03 0.05
Piston
Piston ring
Piston pin
piston outside diameter φ94.453-φ94.467 φ94.43
Inner diameter of piston
pin hole φ20.004-φ20.01 φ20.015
Piston pin and piston pin
bore clearance 0.004-0 .018 0.025
Piston ring
closing
clearance
top ring/second
ring
0.2-0.35 0.5
oilring
0.2-0.7 1.4
Piston ring
and piston
ring groove
clearance
top ring
0.03-0.07 0.08
second ring
0.02-0.06 0.08
Clearance between cylinder
and piston 0.033-0.067 0.07
Outside diameter of piston
pin φ19.992-φ20 φ19.99
Small end of
connecting
rod
inner diameter
φ20.015-φ20.025 φ20.04
Clearance between small
end of connecting rod and
piston pin 0.015-0.033 0.05
Cylinder body and piston specifications Measurement units：mm
Engine cylinder head/valve specification Measurement units：mm
English
version

10
Shift fork/shift fork shaft/crankshaft/balance shaft specifications
Measurement units：mm
items Standard value limit value
Shift fork
Internal diameter of the right fork of the
secondary shaft / Internal diameter of the
left fork of the secondary shaft
φ12.016
-
φ12.043
φ12.045
Spindle fork inner diameter
φ12.016
-
φ12.043
φ12.045
Jaw thickness 4.8-4.9 4.8
shift fork
shaft
Spindle fork shaft outer diameter φ11.973-φ12 φ11.95
Outside diameter of countershaft fork shaft φ11.973-φ12 φ11.95
cylindricity 0.006 ----
crankshaft
Connecting rod small end inner diameter
φ20.015
-
φ20.025
φ20.04
Big end clearance of
connecting rod
axial direction 0.15-0.4 0.7
radial direction 0.008-0.016 0.02
balance
shaft Shaft diameter
φ19.98
-
φ19.993
φ19.96
Clutch/oil pump specifications Measurement units：mm
items Standard value limit value
Clutch handle free clearance
10-20（0.4-0.8
）
-
Clutch
Free spring length
25 25
Friction plate free
thickness
2.95 - 3.05 2.85
Clutch driven plate
flatness
0.1 0.14
Clutch cover and friction
plate clearance
0.1 - 0.3 0.6
oil pump
Radial clearance between
outer and inner rotors
0.06 - 0.15
End clearance between
rotor assembly and cover
plate
0.04 - 0.1
English
version

Front wheel/suspension/steering specifications
items Standard value
limit value
Tire
Pressure
Vacuum tire（regular
edition）200kPa(2.0kgf/cm³，29 psi) -
Inner Tire（regular edition
）
100kPa(1.0kgf/cm³，15 psi) -
Shaft Runout ≤ 0.8 1.0
Rim Runout
radial direction ≤ 0.8 1.0
end face ≤ 0.8 1.0
Wheel dynamic balance - Max 60g
Front shock
absorber
Free spring length/regular
edition/factory edition 475 mm -
Recommended shock
absorber oil Special shock absorbing oil KHL 5W -
shock absorberoil refill
amount 260ml in the damper, 300ml in the damping cylinder, total 560ml -
Rear wheel/suspension specifications
items Standard value limit value
Tire
Pressure
Vacuum tire
（regular edition
）
200kPa(2.0kgf/cm³，29 psi) -
Inner Tire（regular edition） 100kPa(1.0kgf/cm³，15 psi) -
Shaft Runout ≤ 0.8 1.0
Rim
Runout
radial direction ≤ 0.8 1.0
axial direction ≤ 0.8 1.0
Wheel dynamic balance - Max 60g
Rear
shock
absorber
Free spring length/regular
edition/factory edition 215mm/225mm
Recommended shock
absorber oil Special shock absorbing oil KHL 5W
shock absorberoil refill
amount 380ml
Cylinder nitrogen volume 1.2mpa
driving
chain
Size/link AFAM520C2/114
Looseness 30-55 mm
Battery/charging system specifications
items specification
Battery
type MTX4L-FPP
capacity 12V/4AH
Electrical leakage value It can be stored at 25℃
for more than 1 year
voltage（28℃、68℉）fully charged >13.2V
need to be charged <12.8V
Charge Current normal 2A
quick 10A
Magnetor
charging capability 280 W/9,000 rpm
Charging coil resistance（20°C/68°F）0.1-1.0Ω
11
English
version

items Standard value limit value
Front
Brakes
Specify brake fluid DOT 4 -
Brake disc wear indicator - To groove
Brake disc thickness 4.0-4.01 3.5
Brake disc warped - 0.15
Main piston outer diameter 11.000-11.050 11.060
Caliper piston cylinder outside
diameter 27.000-27.050 27.06
Caliper piston cylinder outside
diameter 30.200-30.250 30.260
Rear
Brakes
Specified brake fluid DOT 4 -
Brake disc wear indicator - To groove
Brake disc thickness 4.0-4.01 -3.5
Brake disc warped - 0.15
Main piston outer diameter 9.000-9.050 9.060
Caliper piston outside diameter 22.620-22.670 22.680
Hydraulic brake specification Measurement units：mm
灯/仪表/开关规格
items specification
L
ight
Automatic headlight (high/low light)
LED
Front turn signal/position light
LED
Rear turn signal light
LED
Brake/taillight
LED
License plate lamp
LED
Meter Light
LCD
Turn Signal Light
LED
Neutral indicator light
LCD
Engine oil pressure indicator
LCD
Coolant temperature high indicator
LCD
Malfunction Indicator Lamp（MIL）
LCD
ABS indicator
LCD
Fuse
Spare fuse
15A,10A
Oil pump fan
15A
FI
10A
IGN fuse
15A
Headlights start fuse
15A
ABS2 fuse
10A
ABS1 fuse
15A
The above are regular edition fuse specifications, the following
are factory edition fuse specifications
Spare fuse
10A
，10A
FI
10A
Starting and horn
10A
HEAD
10A
FAN
10A
ECT
Sensor
resistance
40°C (104°F)
1.0
-1.3KΩ
100°C (212°F)
0.1
-0.2KΩ 12
English
version
Light/meter/switch specification

Type of fastener Torque
N.m
Type of fastener Torque
N.m
5mm
screw bolt and nut 6
5mm
bolt 5
6mm
screw bolt and nut 12
6mm
bolt 8
8mm
screw bolt and nut 22
6mm
flange bolt(8mm head，Small
flange
）10
10mm
screw bolt and nut 60
6mm
flange bolt（8mm head，big
flange
）12
12mm
screw bolt and nut 80
6mm
flange bolt（10mm头）
and nut
12
8mm
flange screw bolt and nut 22
10mm
flange screw bolt and nut 60
items QTY
diameter of
screw mm Torque
N.m
Note
spark plug
1 10 14
Large visual hole cover
1 30 5
Small
visual hole cover 1 14 10
Engine
oil bolt 1 16 24 aluminium backing
Oil filter cover bolt
2 6 7-19
Apply proper amount of
oil to the sealing ring
Oil strainer assembly bolt
2 20 11-13
Apply proper amount of
oil to the sealing ring
items QTY D
iameter of
screw mm Torque
N.m
Note
Drain bolt
1 6 10 Copper Gasket
Thermostat cover bolt
2 6 10
Pump chamber bolt
3 6 10
water temperature sensor
1 7 5-8
items QTY D
iameter of
screw mm Torque
N.m
Note
cylinder head stud
4 10 55-60
Oil on thread and end
face
cylinder head stud
4 6 11-13
Camshaft support bolt
8 6 11-13
Cylinder head bolt
6 6 10-12
Tensioner bolt
2 6 11-13
Tensioner bolt plug
1 8 7-9
Exhaust camshaft pressure
reducing valve bolt
1 6 10
·Listed below are the specifications apply to the specified torque fasteners. Other should
tighten to the above standard torque values.
·The standard torque value
13
Torque value - engine part
Cylinder head and valve torque
Cooling system torque value
Engine torque value
English
version

Magneto and starting clutch torque
Box and driveline torque
items QTY D
iameter of
screw mm Torque
N.m
Note
Magneto rotor fastening
nut
1 10 80-90
Magneto stator bolts
2 5 7-9
Trigger bolt
2 5 7-9
Left crankcase cover bolt
8 6 11-13
items QTY D
iameter of
screw mm Torque
N.m
Note
Chain plate
2 6 11-13
Tensioning plate bolt
1 6 10
Crankshaft bolts on both
sides of closing case
12 6 11-13
Oil, replace the new
bolt, fastening method
see the following text
Fastening bolt for cover
plate of left oil pump
3 5 7-9
Clutch and shift mechanism torque
items QTY D
iameter of
screw mm Torque
N.m
Note
Clutch fastening nut
1 18 80-90
Thread fastening glue
Clutch spring bolt
4 6 8-10
Drive gear fastening nut
1 10 115-125
Thread fastening glue
Shift mechanism
positioning plate assembly
1 6 11-13
Right crankcase cover bolt
11 6 11-13
Five star plate bolt
1 6 11-13
14
Torque value of crankshaft, piston, cylinder block and
balance shaft
items QTY D
iameter of
screw mm Torque
N.m
Note
Balancing shaft driven tooth
fastening nut
1 80-90
Balancing shaft drive tooth
fastening nut
1 115-125
English
version

Torque value - body part
Installation area
Specificati
on
Torsion
N.m
Note
Self-tapping nails for the connection of the front brake fluid
pipe pressure plate and the front shock absorbing trim ST4.8 1
Self-tapping nails for connecting rear fender liner and rear
fender rear section ST4.8 1
Self-tapping nails for the connection between OBD and
electrical bracket M4.2 1
Screws for connecting the lower cover plate of the rear
mudguard rear section to the tail trim M5 3
Screws connecting the rear mudguard lower cover to the rear
section of the rear fender M5 3
Internal six-
flower countersunk head screws for connecting the
fuel tank connector mounting plate to the left and right rear
fuel tank M5 5
Oil level sensor mounting plate and the left fuel tank
connected to the internal six flower countersunk head screws M5 5
Phillips pan head screw connecting oil pump to fuel tank M5 5
Phillips pan head screws for instrument and cowl bracket
connection M5 4
Phillips pan head screw connecting the position light to the
rear trim M5 4
Phillips pan head screw for connecting tail light to rear fender
rear section M5 4
Inner six-
flower step screw connecting rear tailcap to rear fuel
tank M5 4
Inner six-
flower step screw connecting the front fender to the
front trim of the fuel tank M5 4
Internal six-flower countersunk head screw connecting the
front gear ring to the front wheel drum M5 5
Threading
glue
Crossed pan head screws for the rear brake pipe clamp to the
flat fork M5 5
Inner six hexagonal flange face bolts connecting the rear
harness clamps to the rear fuel tank M5 4
Inner six flower countersunk head screws for rear gear ring to
rear drum connection M5 5
Threading
glue
Crossed large pan head screws for the fuel filter mounting
bracket to the fuel tank M5 4
Hexagon socket head cap screws for connecting headlight
bracket pressure plate to headlight bracket M5 4
Phillips pan head screw for connecting the roll sensor to the
electrical mounting bracket M5 5
Crossed large pan head screws connecting ECU to rear fuel
tank M5 4
Internal hexagonal countersunk head screw connecting the
seat cushion locking seat to the rear fuel tank M6 8
Hexagonal pan head step screw for front shock trim to front
shock absorber M6 5
Crossed half-round head screws for the chain guard and flat
fork connection M6 8
Hexagon socket flower pan head screws for connecting rear
brake master cylinder to frame M6 8
Inner hexagonal countersunk head screws for connecting the
rear fuel tank protection plate to the rear fuel tank M6 8
Inner six hexagonal flange face bolts for connecting electrical
bracket to fuel tank reinforcement bracket M6 12
Inner six flower hexagonal flange face bolts connecting the
electrical bracket to the rear fuel tank M6 8
Inner hexagonal flower pan head step screws for connecting
headlight trim parts to headlight mounting brackets M6 8
Hexagon socket pan head step screws for connecting the
water reservoir to the frame M6 8
15
Note: The following standard parts are for regular edition models
only
English
version

16
Installation area
Specifica
tion
Torsion
N.m
Note
Hexagon socket flower-
shaped pan head screws for connecting
side bracket flameout switch to side bracket M6 8
Hexagon socket head screws for connecting the left and right
front fuel tanks to the tank mounting bracket M8 22
Hexagon socket head screws in front of the left and right front
fuel tanks connected to the frame M8 22
Hexagon socket head bolts connecting ignition lock to upper
coupling plate M8 22
Inner hexagonal flange bolts connecting the left and right cowl
brackets M5 5
Inner hexagonal flange bolts connecting the oil cooler grille to
the lower shield M5 5
Inner hexagonal flange bolts connecting radiator grill to radiator
M5 5
Inner hexagonal flange bolts connecting the shield mounting
bracket to the left and right front fuel tanks M5 5
Inner hexagonal flange face bolts of the rear brake pedal
connected to the rear brake rocker arm M5 3
Threading
glue
Inner hexagonal flange bolts of headlight and headlight
mounting bracket M5 5
Inner six hexagonal flange face bolts connecting the side
bracket hook bracket to the rear fuel tank M5 5
Inner hexagonal flange bolts of the front brake main pump
connected to the steering handle M6 10
Inner hexagonal flange bolts of the oil cooler connected to the
frame M6 12
Hexagonal flange face bolts connecting the small sprocket cover
to the engine M6 8
Inner hexagonal flange face bolts of muffler mounting bracket
connected to rear fuel tank M6 10
Hexagonal flange face bolts with inner six flowers for connecting
the lower shield to the frame M6 12
Hexagonal flange face bolts with inner six flowers connecting
the hood bracket to the headlight bracket M6 12
Inner six hexagonal flange face bolts connecting the regulator to
the electrical bracket M6 10
Inner hexagonal flange bolts of the radiator connected to the
frame M6 12
Inner six hexagonal flange face bolts connecting the
front brake fluid pipe clamp to the lower coupling plate
M6 10
Inner six hexagonal flange face bolts connecting the
front disc to the front wheel hub M6 12
Threading
glue
Inner hexagonal flange face bolts of front fender to
lower coupling plate M6 8
Inner hexagonal flange bolt for front ABS sensor
mounting M6 10
Inner hexagonal flange bolt for connecting injector cap
to throttle M6 8
Inner hexagonal flange bolt for clutch handle mounting
and connection M6 10
Inner hexagonal flange bolt for connecting horn to
frame M6 12
Inner six hexagonal flange face bolts connecting the air
filter to the frame M6 12
Inner six hexagonal flange face bolts connecting the
lower rear fuel tank mounting bracket to the rear fuel
tank M6 10
Inner six hexagonal flange face bolts connecting the rear
fuel tank reinforcement bracket to the rear fuel tank M6 10
Inner hexagonal flange bolts connecting the rear brake
caliper trim to the rear brake caliper M6 10
English
version

17
Installation area
Specification
Torsion
N.m
Note
Inner six flower hexagonal flange face bolts for the
connection of the rear disc brake disc to the wheel drum
M6 12
Threading
glue
Inner hexagonal flower pan head step bolts for the
connection of the rear water skin to the rear fuel tank M6 10
Hexagonal flange face bolts for rear ABS sensor bracket
to rear caliper bracket connection M6 12
Inner six flower hexagonal flange face bolts for the rear
ABS sensor connected to the bracket M6 8
Inner six flower hexagonal flange face bolts for chain
guide connection to flat fork M6 10
Inner hexagonal flange face bolt of headlight bracket
connected to headlight module M6 12
Inner six hexagonal flange face bolts connecting the shift
lever to the engine M6 12
Inner hexagonal flange surface bolts of ABS and ABS
bracket M6 12
Inner hexagonal flange bolts of the left and right hood
brackets connected to the frame M8 22
Threading
glue
Hexagonal bolts connecting left and right chain
adjustment M8 10
Hexagonal bolts with inner hexagonal flange for
connecting the middle part of the muffler to the frame M8 22
Hexagonal bolts with inner hexagonal flange for
connecting the rear part of muffler to the frame M8 22
Hexagonal bolts with inner hexagonal flange for
connecting the lower coupling plate to the shock
absorber M8 22
Rear bag mounting bolts connecting rear end cover and
rear fender to rear fuel tank M8 22
Inner hexagonal flange bolts connecting the upper
suspension plate to the frame M8 35
Inner hexagonal flange bolts of the upper coupling plate
to the shock absorber M8 22
Inner six hexagonal flange face bolts connecting the
upper mount to the lower mount M8 22
Inner hexagonal flange face bolts of the front brake
caliper connected to the front shock absorber M8 32
Threading
glue
Inner hexagonal flange face bolts of the front shock
absorber connected to the front axle M8 22
Brake arm bolts for the rear brake arm connected to the
frame M8 22
Threading
glue
Rear fuel tank mounting bolts connecting the rear fuel
tank to the frame M8 22
Threading
glue
Hexagonal flange face bolts connecting the rear section
of the rear fender to the rear fuel tank M8 22
Inner hexagonal flange face bolts of the front engine
suspension plate connected to the fuel tank mounting
bracket M8 15
Hexagonal flange face bolts of the front engine
suspension plate connected to the frame M8 22
Sprocket bolt connecting sprocket to U-shaped rocker M8 22
Hexagonal bolt connecting oil level sensor to mounting
plate M10 22
Hexagonal bolts with inner hexagonal flanges connecting
the lower mount to the upper coupling plate M10 35
Threading
glue
Flat head bolts connecting the rear shock to the
triangular rocker M10 44
Hexagonal bolts with inner hexagonal flange for
connecting the rear shock absorber to the frame M10 44
Hexagonal flange face bolts connecting the lower engine
suspension to the engine M10 54
English
version