ENGINE SPECIFICATIONS
2-4
Limit
0.100 mm (0.0039 in)
Valve stem runout
0.010 mm (0.0004 in)
Valve spring
Free length (intake)
41.25 mm (1.62 in)
Limit
39.18 mm (1.54 in)
Free length (exhaust)
42.33 mm (1.67 in)
Limit
40.21 mm (1.58 in)
Spring tilt (intake)
1.7 mm (0.07 in)
Spring tilt (exhaust)
1.7 mm (0.07 in)
Cylinder
Bore
79.000–79.010 mm (3.1102–3.1106 in)
Taper limit
0.008 mm (0.0003 in)
Out of round limit
0.050 mm (0.0020 in)
Piston
Diameter
78.970–78.985 mm (3.1090–3.1096 in)
Measuring point (from piston skirt bottom)
8.0 mm (0.31 in)
Piston-to-cylinder clearance
0.015–0.040 mm (0.0006–0.0016 in)
Piston pin bore inside diameter
17.002–17.013 mm (0.6694–0.6698 in)
Limit
17.043 mm (0.6710 in)
Piston pin outside diameter
16.991–17.000 mm (0.6689–0.6693 in)
Limit
16.971 mm (0.6681 in)
Piston-pin-to-piston-pin-bore clearance
0.002–0.022 mm (0.0001–0.0009 in)
Piston ring
Top ring
Ring
type
Barrel
End gap (installed)
0.15–0.25 mm (0.0059–0.0098 in)
End gap limit
0.50 mm (0.0197 in)
Ring side clearance
0.030–0.065 mm (0.0012–0.0026 in)
Side clearance limit
0.115 mm (0.0045 in)
2nd ring
Ring
type
Taper
End gap (installed)
0.65–0.80 mm (0.0256–0.0315 in)
End gap limit
1.15 mm (0.0453 in)
Ring side clearance
0.020–0.055 mm (0.0008–0.0022 in)
Side clearance limit
0.115 mm (0.0045 in)
Connecting rod
Oil clearance
0.032–0.054 mm (0.0013–0.0021 in)
Bearing color code
Code
2
Black
Code
3
Brown
Code
4
Green
Code
5
Yellow
Code
6
Pink
Crankshaft
Runout limit
0.030 mm (0.0012 in)
Journal oil clearance
0.027–0.045 mm (0.0011–0.0018 in)
Bearing color code
Code
1
Blue
Code
2
Black
Code
3
Brown
Summary of Contents for MT 10 2016
Page 1: ...2016 SERVICE MANUAL MTN1000 MTN1000G B67 28197 E0 ...
Page 2: ......
Page 8: ......
Page 63: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 18 ...
Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 Crankcase and cylinder right side view ...
Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 Timing chain cover and oil pipe right side view ...
Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 Oil pump and oil cooler bottom view ...
Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 Camshaft and balancer shaft top view ...
Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 Crankshaft rear view ...
Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 Crankshaft and transmission top view ...
Page 80: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20020 COOLING SYSTEM DIAGRAMS ...
Page 82: ...COOLING SYSTEM DIAGRAMS 2 37 ...
Page 84: ...CABLE ROUTING 2 39 EAS20021 CABLE ROUTING Handlebar front view ...
Page 86: ...CABLE ROUTING 2 41 Headlight front view ...
Page 88: ...CABLE ROUTING 2 43 Radiator cover right side view ...
Page 90: ...CABLE ROUTING 2 45 Clutch cable and O2 sensor lead right side view ...
Page 92: ...CABLE ROUTING 2 47 Electrical components tray left side view ...
Page 94: ...CABLE ROUTING 2 49 ECU Engine Control Unit left side view ...
Page 96: ...CABLE ROUTING 2 51 Handlebar top view ...
Page 98: ...CABLE ROUTING 2 53 Frame top view ...
Page 100: ...CABLE ROUTING 2 55 Frame top view ...
Page 102: ...CABLE ROUTING 2 57 Frame top view ...
Page 104: ...CABLE ROUTING 2 59 Rear fender top view ...
Page 106: ...CABLE ROUTING 2 61 Rear fender left side view ...
Page 108: ...CABLE ROUTING 2 63 Rear brake hose right side view ...
Page 110: ...CABLE ROUTING 2 65 Front brake hose left side view ...
Page 112: ...CABLE ROUTING 2 67 Front brake hose left side view ...
Page 114: ...CABLE ROUTING 2 69 Hydraulic unit assembly top and left side view ...
Page 116: ...CABLE ROUTING 2 71 Fuel tank bottom and left side view ...
Page 118: ...CABLE ROUTING 2 73 Canister ...
Page 120: ...CABLE ROUTING 2 75 Air filter case and throttle bodies top and left side view ...
Page 122: ...CABLE ROUTING 2 77 Air cut off valve right side view ...
Page 124: ...CABLE ROUTING 2 79 Radiator left side view ...
Page 126: ...CABLE ROUTING 2 81 Radiator right side view ...
Page 128: ...CABLE ROUTING 2 83 Muffler top and left side view ...
Page 130: ...CABLE ROUTING 2 85 ...
Page 183: ...GENERAL CHASSIS 1 4 12 Air scoop bolt 1 5 N m 0 15 kgf m 1 1 lb ft T R 2 1 b b d a a c ...
Page 190: ...GENERAL CHASSIS 2 4 19 TIP Slide the fuel tank rivet in the arrow direction and remove it 1 2 ...
Page 201: ...FRONT WHEEL 4 30 WARNING EWA13500 Make sure the brake hose is routed properly ...
Page 362: ...CONNECTING RODS AND PISTONS 5 79 a ...
Page 378: ...TRANSMISSION 5 95 ...
Page 408: ...AIR INDUCTION SYSTEM 7 15 EAS20071 AIR INDUCTION SYSTEM ...
Page 414: ...AIR INDUCTION SYSTEM 7 21 ...
Page 418: ...IGNITION SYSTEM 8 1 EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM ...
Page 423: ...IGNITION SYSTEM 8 6 ...
Page 424: ...ELECTRIC STARTING SYSTEM 8 7 EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM ...
Page 429: ...ELECTRIC STARTING SYSTEM 8 12 ...
Page 430: ...CHARGING SYSTEM 8 13 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM ...
Page 433: ...CHARGING SYSTEM 8 16 ...
Page 434: ...LIGHTING SYSTEM 8 17 EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM ...
Page 437: ...LIGHTING SYSTEM 8 20 ...
Page 438: ...SIGNALING SYSTEM 8 21 EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM ...
Page 446: ...COOLING SYSTEM 8 29 EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM ...
Page 449: ...COOLING SYSTEM 8 32 ...
Page 450: ...FUEL INJECTION SYSTEM 8 33 EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM ...
Page 540: ...CRUISE CONTROL SYSTEM 8 123 EAS20087 CRUISE CONTROL SYSTEM EAS30544 CIRCUIT DIAGRAM ...
Page 556: ...FUEL PUMP SYSTEM 8 139 EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM ...
Page 559: ...FUEL PUMP SYSTEM 8 142 ...
Page 560: ...IMMOBILIZER SYSTEM 8 143 EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM ...
Page 569: ...IMMOBILIZER SYSTEM 8 152 ...
Page 570: ...ABS Anti lock Brake System 8 153 EAS20085 ABS Anti lock Brake System EAS30843 CIRCUIT DIAGRAM ...
Page 572: ...ABS Anti lock Brake System 8 155 EAS30525 ABS COMPONENTS CHART 1 5 6 7 10 9 8 12 1 2 3 4 11 ...
Page 574: ...ABS Anti lock Brake System 8 157 EAS30844 ABS COUPLER LOCATION CHART 2 1 4 3 5 ...
Page 597: ...ABS Anti lock Brake System 8 180 ...
Page 598: ...STEERING DAMPER SYSTEM 8 181 EAS20259 STEERING DAMPER SYSTEM EAS32036 CIRCUIT DIAGRAM ...
Page 603: ...STEERING DAMPER SYSTEM 8 186 ...
Page 606: ...ELECTRICAL COMPONENTS 8 189 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 22 23 24 11 21 ...
Page 626: ...ELECTRICAL COMPONENTS 8 209 ...
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