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Old 09-24-2011, 10:11 PM   #19
eakins
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Joined: May 2002
Location: Fort Collins, Colorado
Oddometer: 17,852
Spark plug – 8 ftlbs (96 in lbs)
TDC inspection hole plug – 16.5 ft (198)
Oil drain – 17.5 ft (210) – use 13mm socket
Oil filter cover – 8flbs (96 in) stock – 4ft (48) alum cover
Oil – 2.5 qt w/ filter (10w-40)
Cylinder head cover bolt – 7ft (84)
Valves – adj on the tight end (engine runs quiter)

Handle bar clamp bolt – 16.5 ft (198)
Triple clamp bolts: upper – 21 ft (252) / lower 19 ft (228)
Steering stem (top of triple clamp) top nut/cap – 65 ft lbs
Front wheel axel – 47 ft : tighten first, cycle shocks 5x
Front wheel axel clamp bolts – 7 ft (84 in) : tighten next, top bolt first
Fork top cap – 16.5 ft (198)
Fork preload = 10-20mm
Fork oil height = 6.5” / 16 oz (5.9 lowered – need 2 qt)

Front brake caliper bolts – 19ft (228)
Fr brake Bleed nipple – 6 ft (72)
Fr Brake pad mounting pin – 13lb (156)
Fr brake hose banjo bolts – 16.5ft (198)

Rear brake caliper pad – 13 ft (156)
Rear wheel axel nut – 72.5 ft (cotter pin) / 79.5 (fuji nut)
Rear shock – upper bolt 40 ftlb , lower bolt 37 Nm (cogent) 55nm (stock)
Rear suspension linkage - Dog bones fuji-nuts (both) – 72.5 flbs
Rear suspension linkage – frame fuji-nuts – 58 ftlbs
Chain – 525, 110 link, 14/42 sprockets
Chain free play – 1.2–1.8 in (30-45 mm) 1.2 to 1.8 inches of slack in the middle of the chain
Chain stretch limit: Loosen your axle nut and adjust your chain so there is no play in it. Count out 20 pitches (21 pins) measure between the centerlines of the 1st and 21st pin. 319.4mm (12.6") is the service limit
Swing arm bolt – 55.5 flbs

Counter sprocket bolts - 4.5 ft lbs (54 in) (shoulder/raised area goes in towards engine)
Suzuki counter sprocket seal retainer – part# 24751-32E00
Rear Sprocket – 19.5 ftlbs (234 in)

Cogent rear shock
-lower red adjuster – rebound, 42 click total, out/down is softer
-upper small adjuster – compression, out/CCW is softer
-200lbs w/ gear – 4 out past middle settings.


Quality Bearings:

-Front wheel bearings: SKF 6003-2RS
2 - 17 x 35 x 10
-Front wheel seal:
2 - 23x35x7 (09284-23001 – Suzuki #)

-Rear wheel bearings: SKF 6204-2RS
2 - 20x47x14
-Rear wheel seal (brake side):
1 - 26x47x7 (09283-26019 – Suzuki #)

-Cush Hub bearing: SKF 6205-2RS
1 - 25x52x15
-Cush Seal:
1 - 35x52x7 (09283-34003 – Suzuki #)
-------------------------------------------
Two 6003-2RS
Two 6204-2RS
One 6205-2RS
---------------------------------------------
Go for sealed both sides European or Jap bearings if you don't mind paying more . . . I sure don't.
Any brands like SKF, FAG, NSK etc.
If you want a good Jap sealed bearing for the rear axle hub (x 2) get Honda ones :
part number 96150-6204010 ( generic 6204 bearing ) 20 x 47 x 14 mm size.

Cush drive bearing is a 6205 generic 25 x 52 x 15mm
Honda part number 96150-6205010

Front wheel size is 6003 generic 17 x 35 x 10mm
Honda part # 91065-KA3-832

Before you pay for the Honda ones check they are made in Japan and sealed both sides !

Spark plugs:
Denso irdidium - 5364 (IU31)
Standard ngk - CR10E
NGK irdium - CR10EIX

-Lock nut from 2008 and newer: 08319-2118a
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eakins screwed with this post 08-04-2014 at 10:22 PM
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