Gen II OEM parts guide/torque spec/wrench guide

Discussion in 'Gen II Busa Information' started by ks-waterbug, Dec 25, 2008.

  1. ks-waterbug

    ks-waterbug Group Buy Guy Donating Member Registered

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    Ok, been mulling this one over for sometime and its finally here but I need the oRgs help! This is your one stop shop for WHATs the OEM part number or size of everything Busa (Gen II). Sorry Gen I owners...

    Let the posting begin and I'll update this post to reflect what you come up with....

    ******************************************************************
    DIY MAINTENANCE DOCUMENTS

    ALL LINKS IN BLUE ARE CLICKABLE...


    Wheels/Tires
    Front size 120/70/17
    OEM Tire bt015

    Rear size 190/50/17
    OEM tire bt015


    Chain
    Stock length 114
    Stock brand RK GB50GSV Z4
    (AML)
    17-42 132 links will put you right at 64 inches, (6" over)
    Approx 150 links should give you full adjustment (6" over)
    Brakes
    OEM Front PAD & SHIM SET 59100-29840 (320mm DiscTokico - Front twin 6 piston calliper)
    OEM Rear PAD SET 69100-15820 (260mm Back single 4 piston calliper)
    (AML)
    All your Braking needs - CycleBrakes.com oRg Sponsor

    Sprockets
    Front teeth 18 - SPROCKET,ENGINE 27510-15H00, (36MM) Torque 105 lb-ft / 145 N.m (NOTE: Speed sensor ROTOR bolt torque is only 20 lb-ft / 28 N.m)(Speed sensor mounting bolts Torque 4.7 lb-ft / 6.5 N.m).
    Rear teeth 43 - SPROCKET,REAR 43 64511-40F50, Torque for 5(ea) bolts 43.5 lb-ft / 60 N.m
    (AML)

    Headlight bulb
    Highbeam H9
    Wedge Bulb (corners of headlight) 194 Cross Reference: T10, W5W, & 158.
    Lowbeam H7
    (AML)
    HID oRg Group Buy Sponsor - XenonKing.com

    Turnsignals
    OEM LAMP REAR RH 35603-15H00
    OEM LAMP REAR LH 35604-15H00
    OEM BULB 09471-12186
    OEM LAMP FRONT RH 35601-15H00
    OEM LAMP FRONT LH 35602-15H00
    OEM BULB 09471-12186
    Bulb type is PY21W. The pins are slightly offset (ie not 180 degrees apart)


    Spark plugs
    Factory Denso IU27D or NGK CR9EIA-9
    Aftermarket


    Battery
    Yuasa
    OEM YT12A-BS - 6" x 3 7/16" x 4 3/16" 176 Cold Cranking Amps
    (AML) YTZ14S - 6" x 3 7/16" x 4 3/8" 235 Cold Cranking Amps


    Air Filter
    OEM FILTER ASSY 13780-15H00
    (AML)
    PiperCross - MPX043
    K&N - SU-1308 or SU-1308R (Race only)
    BMC - 52904
    BMC RACE - FM529/04Race
    DNA - PS13S080R



    Oil Filter
    OEM Part #16510-03G00-X07
    (AML)
    AMSOil SMF 109
    Bike Master 314-0025
    Champion PH7016
    Cycle Power 314-1919
    Emgo 10-55662
    Emgo 10-55660
    Fram PH6018
    Hi-Flo HF138
    J.C.Whitney ZX063166P
    K&N - KN-138 or KN-138C (Chrome)
    K&P Engineering - S2 (Re-usable)
    NAPA 1359 / WIX 51359
    NAPA PS7937
    Parts Unlimited
    Per-Form J-509
    ProPart 01-0029
    Purolator ML16818
    Scotts Performance Reusable - #17255
    STP SMO-18
    Suzuki 16510-03G00-X07
    VESRAH vsf-3009
    WIX 57937



    Oil 10W40 Oil drain plug torque spec - 23 N-m, 16.5 ft lbs
    Oil Change 3.275 quarts or 3100cc
    With Filter Change 3.487 quarts or 3300cc
    Overhaul 4.226 quarts or 4000cc
    OEM
    (AML)
    Amsoil
    Mobile 1

    Radiator Fluid
    Good read about radiator fluids by Dave Kimmey

    Clutch
    Number of Clutch Springs: 6
    Number of Clutch Plates: 10 Drive; 9 Driven
    (AML)
    APE RACING - HAYABUSAZONE.COM - oRg Sponsor
    SCHNITZ RACING - oRg Sponsor

    Rear axle nut size
    Metric 36mm - Torque to 72.5 ft lbs
    US 1-7/16"


    Front axle nut size
    Metric 24mm (can use spark plug kit wrench to remove, inserted backwards)

    Steering Stem Head Nut
    65.0 lb-ft ; (#6 - steering stem head nut), K8 Hayabusa manual, pg 6B-5.

    Gen II generator output
    400 Watts max @ 5,000r/min


    Body Panel numbers
    Micor fiche - oRg Sponsor / MotorSportsSuperCenter.com




    AML After Market List


    GEN I Wire Diagram

    **************************************************
    FOR ALL YOUR MOTORCYCLE NEEDS CLICK ME!
    **************************************************
    2008 HAYABUSA TIGHTENING TORQUE
    (Remember! Some of those need to be torqued down in stages and in sequence)
    Information provided by - GRUNTMAX (psychobike.com)
    ITEM N-m, kgf-m, lb-ft
    Exhaust pipe bolt
    23
    2.3
    16.6

    Muffler mounting nut
    23
    2.3
    16.6

    Muffler joint nut
    25
    2.5
    18.0

    Speed sensor rotor bolt
    18
    1.8
    13.0

    Engine sprocket nut
    145
    14.5
    105.0

    Engine mounting bolt and nut
    (M:12)
    75
    7.5
    54.0

    (M:10)
    55
    5.5
    40.0

    Engine mounting thrust adjuster
    10
    1.0
    7.0

    Engine mounting thrust adjuster lock nut
    45
    4.5
    32.5

    Engine mounting pinch bolt
    35
    3.5
    25.5

    Cylinder head cover bolt
    14
    1.4
    10.0

    Spark plug
    11
    1.1
    7.0

    Cam chain guide bolt
    10
    1.0
    7.0

    Camshaft holder bolt
    10
    1.0
    7.0

    Cam chain tension adjuster bolt
    8
    0.8
    6.0

    Cam chain tension adjuster mounting bolt
    10
    1.0
    7.0

    Cylinder head side bolt
    14
    1.4
    10.0

    Cam chain tensioner bolt
    10
    1.0
    7.0

    Cylinder head bolt
    (M:10)
    52
    5.2
    37.5

    (M:6)
    10
    1.0
    7.0

    Cylinder nut
    10
    1.0
    7.0

    PAIR pipe nut
    10
    1.0
    7.0

    Water bypass union
    14
    1.4
    10.0

    Water inlet connector bolt
    10
    1.0
    7.0

    Oil hose union bolt
    20
    2.0
    14.5

    Clutch cover bolt
    10
    1.0
    7.0

    Clutch sleeve hub nut
    95
    9.5
    68.5

    Clutch spring set nut
    10
    1.0
    7.0

    Clutch spring support nut
    23
    2.3
    16.6

    Starter clutch cover bolt
    10
    1.0
    7.0

    Starter idle gear cover bolt
    10
    1.0
    7.0

    Starter clutch cover plug
    11
    1.1
    8.0

    Valve timing inspection plug
    23
    2.3
    16.6

    Starter clutch bolt
    55
    5.5
    40.0

    Generator cover bolt
    10
    1.0
    7.0

    Generator roter bolt
    120
    12.0
    87.0

    Generator stator set bolt
    10
    1.0
    7.0

    Crankshaft position sensor set bolt
    5.5
    0.55
    4.0

    Gearshift cover bolt
    10
    1.0
    7.0

    Gearshift cam stopper bolt
    10
    1.0
    7.0

    Gearshift cam stopper plate bolt
    10
    1.0
    7.0

    Gearshift arm stopper bolt
    19
    1.9
    13.5

    Oil pressure switch
    14
    1.4
    10.0

    Crankcase bolt
    [M:6]
    11
    1.1
    8.0

    [M:8]
    26
    2.6
    19.0

    [M:9]
    32
    3.2
    23.0

    [M:10]
    50
    5.0
    36.0

    Oil gallery plug
    [M:6][M:8]
    10
    1.0
    7.0

    [M10]
    16
    1.6
    11.5

    [M16]
    35
    3.5
    26.5

    Oil drain plug
    23
    2.3
    16.5

    Piston cooling oil jet bolt
    10
    1.0
    7.0

    Oil jet (For generator)
    5
    0.5
    3.5

    Oil pump mounting bolt
    10
    1.0
    7.0

    Conrod bearing cap bolt
    (Initial)
    35
    3.5
    25.5

    (Final)
    67
    6.7
    48.5

    Bearing retainer screw
    8
    0.8
    6.0

    Cam chain guide retainer screw
    8
    0.8
    6.0

    Balancer arm bolt
    10
    1.0
    7.0

    Balancer cover bolt
    10
    1.0
    7.0

    Breather pipe bolt
    10
    1.0
    7.0

    Oil strainer bolt
    10
    1.0
    7.0

    Oil pan bolt
    10
    1.0
    7.0

    Oil pipe bolt
    [M:6]
    10
    1.0
    7.0

    Oil pipe union bolt
    [M:14]
    28
    2.8
    20.5

    FI ASYSTEM AND INTAKE AIR SYSTEM

    Camshaft position sensor mounting bolt
    8
    0.8
    6.0

    Intake air temperature sensor
    18
    1.8
    13.0

    Fuel pressure check plug
    10
    1.0
    7.0

    Fuel pressure regulator mounting screw
    3
    0.3
    2.0

    Fuel filter cap mounting screw
    3
    0.3
    2.0

    Fuel delivery pipe mounting screw
    5
    0.5
    3.5

    Fuel pump mounting screw
    5
    0.5
    3.5

    COOLING AND LUBRICATION SYSTEM

    Impeller securing bolt
    8
    0.8
    6.0

    Water pump cover bolt
    6
    0.6
    4.5

    Water pump mounting bolt
    10
    1.0
    7.0

    Cooling fan thermo-switch
    17
    1.7
    12.5

    Engine coolant temperature sensor
    18
    1.8
    13.0

    Thermostat case bolt
    10
    1.0
    7.0

    Oil cooler hose bolt
    10
    1.0
    7.0

    CHASSIS

    Steering stem head nut
    90
    9.0
    65.0

    Steering stem lock nut
    80
    8.0
    58.0

    Steering damper bolt
    23
    2.3
    16.6

    Front fork upper clamp bolt
    23
    2.3
    16.6

    Front fork lower clamp bolt
    23
    2.3
    16.6

    Front fork cap bolt
    23
    2.3
    16.6

    Front fork inner rod lock nut
    29
    2.9
    20.8

    Front fork damper rod bolt
    40
    4.0
    29.0

    Front axle
    100
    10.0
    72.5

    Front axle pinch bolt
    23
    2.3
    16.6

    Handlebar clamp bolt
    10
    1.0
    7.0

    Handlebar holder nut
    35
    3.5
    25.5

    Front brake master cylinder mounting bolt
    10
    1.0
    7.0

    Front brake caliper mounting bolt
    39
    3.9
    28.0

    Front brake caliper housing bolt
    21
    2.1
    15.0

    Brake hose union bolt
    23
    2.3
    16.6

    Clutch master cylinder mounting bolt
    10
    1.0
    7.0

    Clutch hose union bolt
    23
    2.3
    16.6

    Air bleeder valve
    7.5
    0.75
    5.5

    Brake disc bolt (Front)
    23
    2.3
    16.6

    Brake disc bolt (Rear)
    35
    3.5
    25.5

    Rear brake caliper mounting bolt
    26
    2.6
    19.0

    Rear brake caliper housing bolt
    30
    3.0
    21.5

    Rear brake master cylinder mounting bolt
    10
    1.0
    7.0

    Rear brake master cylinder rod lock nut
    18
    1.8
    13.0

    Front footrest bracket mounting bolt
    26
    2.6
    19.0

    Swing arm pivot shaft
    15
    1.5
    11.0

    Swing arm pivot nut
    100
    10.0
    72.5

    Swing arm pivot lock nut
    90
    9.0
    65.0

    Torque link nut (Front)
    28
    2.8
    20.5

    Torque link nut (Rear)
    35
    3.5
    25.5

    Cushion lever mounting nut
    78
    7.8
    56.5

    Cushion rod mounting nut
    78
    7.8
    56.5

    Rear shock absorber mounting nut
    50
    5.0
    36.0

    Rear axle nut
    100
    10.0
    72.5

    Rear sprocket nut
    60
    6.0
    43.5

    Side-stand mounting bolt
    95
    9.5
    68.5

    Cowling brace bolt and nut
    23
    2.3
    16.6
     
  2. freponyryd

    freponyryd Registered

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    front tire bt015 120/70/17

    rear tire bt015 190/50/17
     
  3. Got-Busa?

    Got-Busa? Donating Member Registered

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    I'm to busy to go look today at the chain but the stock gearing is 18/43.
     
  4. ks-waterbug

    ks-waterbug Group Buy Guy Donating Member Registered

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    Keep em coming along with suggestions of what else should be included... This is your oRg
     
  5. BusaWizard

    BusaWizard On a Steel Horse I ride. Donating Member Registered

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    Body panels numbers.
     
  6. Dozerdriver

    Dozerdriver Registered

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    Rear axle nut is a 36 mm
     
  7. BA BUSA

    BA BUSA MotoGP Wannabe Donating Member Registered

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    chain 114 links
    Posted via Mobile Device
     
  8. ks-waterbug

    ks-waterbug Group Buy Guy Donating Member Registered

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    Gotem...
     
  9. EarlyBird

    EarlyBird Donating Member Registered

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  10. Gardzilla

    Gardzilla Registered

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    How about Gen II spring rates? Has anything changed?

    Gen I Fork Springs = 0.850 kg/mm
    Gen I Shock Spring = 13.1 kg/mm
     
  11. ks-waterbug

    ks-waterbug Group Buy Guy Donating Member Registered

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    Anyone got the answer to this one?
     
  12. Busa08

    Busa08 Guest

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  13. Greenbean

    Greenbean Registered

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    This is good info,

    Thanks...
    :cool:
     
  14. CCbusa05

    CCbusa05 Donating Member Registered

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    Fairng and fender nylon clips/pins

    For Gen I or Gen II :)

    100_3010.jpg
     
  15. demetrie6

    demetrie6 Registered

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    wot about front fork width still 43mm?
     
  16. busatim

    busatim Registered

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    Shift Lever ( How many splines on the lever going into tranny have ? And what size is the part that sticks out of the Tranny ? ) Thanks, busatim
     
  17. ks-waterbug

    ks-waterbug Group Buy Guy Donating Member Registered

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    So, whats everyone think? Good idea or no...? Are we missing anything that should be on here? I see some of the members questions are still unanswered...
     
  18. busaville

    busaville Registered

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    weight of oil?
     
  19. ks-waterbug

    ks-waterbug Group Buy Guy Donating Member Registered

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    Good catch...
     
  20. busaville

    busaville Registered

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    10w-40 gen II
     

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