Motorcycle Tune Up & Periodic Maintenance Specifications
Disclaimer: thesmallengineshop.net has made every effort to provide accurate tune-up and maintenance specification's, but it is up to the user to verify all information using the correct owners manual or repair manual for the motorcycle in question. thesmallengineshop.net is not responsible for how this information is used, and the information is provided for educational purposes only.
The proper tune-up and maintenance specifications should be used whenever maintenance and tune-up service work is performed on any motorcycle, but this information is not always easy to find. This webpage will try and provide basic tune-up and maintenance specifications needed to perform the most common motorcycle routine maintenance and service work. This webpage is a work in progress, and new content will be added on a regular basis.
If you find something is missing, or you need information on a year, make and model motorcycle that isn't listed, than please request the information by contacting us using the thesmallengineshop.net online forum. Link to the forum is at the top right of the page.
Instructions: Find your year, make and model motorcycle in the list below, and click on the link. The information will appear below the link. If you click on the link a second time, the information will close or disappear.
Honda:
- 1981-1991 Honda XR100 and XR100R
1981-1991 Honda XR100 and XR100R Tune-Up and Periodic Maintenance Specifications:
Tire Inflation:
XR100 - Front: 18psi, Rear: 20psi
XR100R - Front: 14psi, Rear: 18psi
Rear Axle Nut Torque Specification:
1981-1982 XR100 - 29 to 36 ft.-lb.
1983-1984 XR100 - 40 to 50 ft.-lb.
XR100R - 40 to 50 ft.-lb.
Final Drive Chain:
Free Play: 20mm or 3/4 inch
Valve Clearance:
Intake - 0.002 inch
Exhaust - 0.002 inch
Spark Plug:
1980-1981 XR100 - NGK C7HS
1982-1984 XR100 - NGK CR7HS
XR100R - NGK CR6HS
Spark Plug Gap:
Spark Plug Gap - 0.024 to 0.028 inch
Contact Breaker Point Gap:
0.012 to 0.016 Inch (If Applicable)
Recommended Oil:
10W-40 For all temperature ranges
Engine Oil Capacity:
Approximately 1 US Quart
Front Brake and Clutch Lever Freeplay:
Front Brake Lever Freeplay - 3/4 to 1 1/4 inch
Clutch Lever Freeplay - 3/8 to 3/4 inch
(Freeplay is end lever travel until clutch or brake is applied)
Throttle Grip Freeplay:
Throttle Grip Rotational Freeplay - 1/8 to 1/4 inch
Rear Brake Freeplay:
Rear Brake Freeplay - 3/4 to 1 1/4 inch
- 1979-1985 Honda XL100S
1979-1985 Honda XL100S Tune-Up and Periodic Maintenance Specifications:
Tire Inflation:
1979-1985 - Front: 21psi, Rear: 21psi
Rear Axle Nut Torque Specification:
1979-1980 - 43 to 58 ft.-lb.
1981-1982 - 29 to 36 ft.-lb.
1983-1985 - 40 to 50 ft.-lb.
Final Drive Chain:
Free Play: 20mm or 3/4 inch
Valve Clearance:
Intake - 0.002 inch
Exhaust - 0.002 inch
Spark Plug:
1979-1985 - NGK CR7HS
Contact Breaker Point Gap:
0.012 to 0.016 Inch (If Applicable)
Spark Plug Gap:
Spark Plug Gap - 0.024 to 0.028 inch
Recommended Oil:
10W-40 For all temperature ranges
Engine Oil Capacity:
Approximately 1 US Quart
Front Brake and Clutch Lever Freeplay:
Front Brake Lever Freeplay - 3/4 to 1 1/4 inch
Clutch Lever Freeplay - 3/8 to 3/4 inch
(Freeplay is end of lever travel until clutch or brake is applied)
Throttle Grip Freeplay:
Throttle Grip Rotational Freeplay - 1/8 to 1/4 inch
Rear Brake Freeplay:
Rear Brake Freeplay - 3/4 to 1 1/4 inch
- 1979-1984 Honda XR500 & XR500R
1979-1984 Honda XR500 & XR500R Tune-Up and Periodic Maintenance Specifications:
Tire Inflation:
Rear:
4.60-17 4PR - 21 psi
5.10-17 6PR - 11 psi
5.10-17 4PR - 21 psi
4.60-18 4PR - 21 psi
4.60-18 6PR - 17 psi
110/90-17 6PR - 14 psi
130/80-17 6PR - 14 psi
110/100-18 64M - 15 psi
Front:
3.00-21 6PR - 14 psi
3.00-21 4PR - 21 psi
3.00-23 6PR - 15 psi
3.00-23 4PR - 21 psi
90/80-21 6PR - 15 psi
90/90-21 6PR - 14 psi
80/100-21 51M - 15 psi
Rear Axle Nut Torque Specification:
Dual Shock models - 51 to 80 ft.-lb.
All other models - 58 to 80 ft.-lb.
Final Drive Chain:
Dual Shock models - 0.8 inch
Pro-Link models - 1 3/8 to 1 3/4 inch
Valve Clearance:
Intake - 0.002 inch
Exhaust - 0.004 inch
Valve Adjuster Lock Nut Torque Specification:
1979-1982 models - 11 to 13 ft.-lb.
1983-1984 XR500R - 13 to 16 ft.-lb.
Spark Plug:
1979-1981 - NGK D8EA
1982 - NGK DR8ES-L
1983-1984 NGK DPR8EA-9
Contact Breaker Point Gap:
N/A
Spark Plug Gap:
Spark Plug Gap - 0.032 to 0.036 inch
Recommended Oil:
10W-40 For all temperature ranges
Oil Drain Plug Torque Specifications:
Wet Sump models Only - 22 to 29 ft.-lb.
Engine Oil Capacity:
1979-1982 - 1.6 US quart
1983-1984 - 2.1 US quart
Front Brake and Clutch Lever Freeplay:
Front Brake Lever Freeplay - 1 to 1 1/4 inch
Clutch Lever Freeplay - For XR500, 1981-1982 XR500R - 5/8 to 1 inch
All others - 3/8 to 3/4 inch
Throttle Grip Freeplay:
Throttle Grip Rotational Freeplay - 1/8 to 1/4 inch
Rear Brake Freeplay:
Rear Brake Freeplay - 3/8 to 5/8 inch
- 1982-1984 Honda V45 Magna VF750C
1982-1984 Honda V45 Magna VF750C Tune-Up and Periodic Maintenance Specifications:
Tire Inflation:
Rear: 32 psi
Front: 32 psi
Front Fork Air Pressure: 6-14 psi
Rear Axle Nut Torque Specification:
43 to 58 ft.-lb.
Front Axle Nut Torque Specification: 40 to 47 ft.-lb.
Front Axle Holder Nuts Torque Specification: 13 to 18 ft.-lb.
Oil Drain Plug Torque Specification: 25 to 29 ft.-lb.
Cylinder Head Drain Bolt Torque Specification: 7 to 10 ft.-lb.
Final Drive Oil Capacity: 3.7 ounces
Spark Plug Torque Specification:
n/a. If installing new plug, tighten until gasket makes contact with head, than tighten another
1/2 turn. For a used plug only tighten 1/4 turn after gasket makes contact with head.
Valve Clearance:
Intake - 0.005 inch
Exhaust - 0.005 inch
Spark Plug:
NGK DPR8RA-9
Spark Plug Gap:
0.031 to 0.035 inch
Recommended Oil:
10W-40 Oil Recommended for Motorcycles (Ambient temps 0F and greater)
Final Drive Oil: Hypoid Gear Oil API GL-5 (1982-1983 use SAE 90 above 41F and SAE 80 below 41F)
(1984 and later model use SAE 80 for all temps)
Engine Oil Capacity:
3.1 quarts (With Filter Change)
Front Brake Lever Free Play: 3/4 to 1-1/4 inch
Rear Brake Drum Pedal Free Play: 3/4 to 1-1/4 inch
Recommended Hydraulic Clutch Fluid: DOT 3 or DOT 4
Choke Lever Freeplay:
0.08 to 0.12 inch
Throttle Grip Freeplay:
Throttle Grip Rotational Freeplay - 1/8 to 1/4 inch
Brake Fluid Type:
DOT 3 or DOT 4
Coolant Type:
Ethylene glycol containing anti-corrosion inhibitors for aluminum engines
Coolant Mixture:
1/2 Distilled Water and 1/2 Antifreeze (50:50)
- 1982-1983 Honda V45 Sabre VF750S
1982-1983 Honda V45 Sabre VF750S Tune-Up and Periodic Maintenance Specifications:
Tire Inflation:
Rear: 32 psi
Front: 32 psi
Front Fork Air Pressure: 6-14 psi
Rear Axle Nut Torque Specification:
43 to 58 ft.-lb.
Front Axle Nut Torque Specification: 40 to 47 ft.-lb.
Front Axle Holder Nuts Torque Specification: 13 to 18 ft.-lb.
Oil Drain Plug Torque Specification: 25 to 29 ft.-lb.
Cylinder Head Drain Bolt Torque Specification: 7 to 10 ft.-lb.
Final Drive Oil Capacity: 3.7 ounces
Spark Plug Torque Specification:
n/a. If installing new plug, tighten until gasket makes contact with head, than tighten another
1/2 turn. For a used plug only tighten 1/4 turn after gasket makes contact with head.
Valve Clearance:
Intake - 0.005 inch
Exhaust - 0.005 inch
Spark Plug:
NGK DPR8RA-9
Spark Plug Gap:
0.031 to 0.035 inch
Recommended Oil:
10W-40 Oil Recommended for Motorcycles (Ambient temps 0F and greater)
Final Drive Oil: Hypoid Gear Oil API GL-5 (1982-1983 use SAE 90 above 41F and SAE 80 below 41F)
(1984 and later model use SAE 80 for all temps)
Engine Oil Capacity:
3.1 quarts (With Filter Change)
Front Brake Lever Free Play: 3/4 to 1-1/4 inch
Rear Brake Drum Pedal Free Play: 3/4 to 1-1/4 inch
Recommended Hydraulic Clutch Fluid: DOT 3 or DOT 4
Choke Lever Freeplay:
0.08 to 0.12 inch
Throttle Grip Freeplay:
Throttle Grip Rotational Freeplay - 1/8 to 1/4 inch
Brake Fluid Type:
DOT 3 or DOT 4
Coolant Type:
Ethylene glycol containing anti-corrosion inhibitors for aluminum engines
Coolant Mixture:
1/2 Distilled Water and 1/2 Antifreeze (50:50)
- (May have appeared in 1984) 1985-1987 Honda V45 Magna VF700C
(may have appeared in 1984) 1985-1987 Honda V45 Magna VF700C Tune-Up and Periodic Maintenance Specifications:
Tire Inflation:
Rear: 32 psi
Front: 32 psi
Front Fork Air Pressure: 6-14 psi
Rear Axle Nut Torque Specification: 1982-1986 43 to 58 ft.-lb., 1987 and later 61-76 ft-lb
Front Axle Nut Torque Specification: 40 to 47 ft.-lb.
Front Axle Holder Nuts Torque Specification: 13 to 18 ft.-lb.(standard axle)
Front Axle Pinch Bolts Torque Specification: 1982-1985 11-18 ft-lb, 1986 14-22 ft-lb, 1987 and later 13-18 ft-lb
Oil Drain Plug Torque Specification: 25 to 29 ft.-lb.
Cylinder Head Drain Bolt Torque Specification: 7 to 10 ft.-lb.
Final Drive Oil Capacity: 3.7 ounces
Spark Plug Torque Specification:
n/a. If installing new plug, tighten until gasket makes contact with head, than tighten another
1/2 turn. For a used plug only tighten 1/4 turn after gasket makes contact with head.
Valve Clearance: (1982-1985)
Intake - 0.005 inch
Exhaust - 0.005 inch
Valve Clearance : (1986 and later)
Intake - .006 inch
Exhaust - .006 inch
Spark Plug:
NGK DPR8RA-9
Spark Plug Gap:
0.031 to 0.035 inch
Recommended Oil:
10W-40 Oil Recommended for Motorcycles (Ambient temps 0F and greater)
Final Drive Oil: Hypoid Gear Oil API GL-5 (1982-1983 use SAE 90 above 41F and SAE 80 below 41F)
(1984 and later model use SAE 80 for all temps)
Engine Oil Capacity:
3.1 quarts (With Filter Change)
Front Brake Lever Free Play: 3/4 to 1-1/4 inch
Rear Brake Drum Pedal Free Play: 3/4 to 1-1/4 inch
Recommended Hydraulic Clutch Fluid: DOT 3 or DOT 4
Choke Lever Freeplay:
0.08 to 0.12 inch
Throttle Grip Freeplay:
Throttle Grip Rotational Freeplay - 1/8 to 1/4 inch
Brake Fluid Type:
DOT 3 or DOT 4
Coolant Type:
Ethylene glycol containing anti-corrosion inhibitors for aluminum engines
Coolant Mixture:
1/2 Distilled Water and 1/2 Antifreeze (50:50)
Kawasaki:
