Service Data

ITEM

STANDARD

LIMIT

Valve diameter

IN.

23 (0.9)

EX.

20 (0.8)

Valve clearance (when cold)

IN.

0.10 - 0.15 (0.004 - 0.006)

EX.

0.18 - 0.23 (0.007 - 0.009)

Valve-guide to valve-stem clearance

IN.

0.020 - 0.047 (0.0008 - 0.0019)

EX.

0.030 - 0.057 (0.0012 - 0.0022)

Valve stem deflection

IN. & EX.

0.35 (0.014)

Valve guide I.D.

IN. &EX.

5.000 - 5.012 (0.1969 - 0.1973)

Valve stem O.D.

IN.

4.965 - 4.980 (0.1955 - 0.1961)

EX.

4.955 - 4.970 (0.1950 - 0.1957)

Valve stem runout

IN. & EX.

0.05 (0.002)

Valve face thickness

IN. & EX.

0.5 (0.02)

Valve stem end length

IN. & EX.

2.5 (0.10)

Valve seat width

IN. & EX.

0.9 - 1.1 (0.035 - 0.043)

Valve head radial runout

IN. & EX.

0.03 (0.001)

Valve spring free length (IN. & EX.)

INNER

35.0 (1.38)

OUTER

38.4 (1.51)

Valve spring tension (IN. & EX.)

INNER

5.6 - 6.6 kgf (12.3 - 14.6 lbs) at length 28 mm (1.10 in)

OUTER

12.8 - 15.0 kgf (28.2 - 33.1 lbs) at length 31.5 mm (1.24 in)

CAMSHAFT + CYLINDER HEAD Unit: mm (In)

ITEM

STANDARD

LIMIT

Cam height

IN.

33.13 - 33.17 (1.3043 - 1.3059)

32.83 (1.2925)

EX.

32.85 - 32.89 (1.2933 - 1.2949)

32.55 (1.2815)

Camshaft journal oil clearance

IN. & EX.

0.032 - 0.066 (0.0013 - 0.0026)

0.150 (0.0059)

Camshaft journal holder I.D.

IN. & EX.

22.012 - 22.025 (0.8666 - 0.8671)

Camshaft journal O.D.

IN. & EX.

21.959 - 21.980 (0.8645 - 0.8654)

Camshaft runout

IN. & EX.

0.10 (0.004)

Cam chain pin (at arrow "3")

24th pin

Rocker arm I.D.

IN. & EX.

12.000 - 12.018 (0.4724 - 0.4731)

Rocker arm shaft O.D.

IN. & EX.

11.973 - 11.984 (0.4714 - 0.4718)

Cylinder head distortion

0.20 (0.008)

CYLINDER + PISTON + PISTON RING

Unit: mm (in)

ITEM

STANDARD

LIMIT

Compression pressure

1 000 - 1 500 kPa /10 - 15 kgf/cm2\ \ 142-213 psi )

800 kPa (8 kgf/cm2\ V 114 psi /

Compression pressure difference

200 kPa (2 kgf/cm2\ V 28 psi /

Piston-to-cylinder clearance

0.040 - 0.050 (0.0016 - 0.0020)

0.120 (0.0047)

Cylinder bore

62.600 - 62.615 (2.4646 - 2.4652)

62.690 (2.4681)

Piston diameter

62.555 - 62.570 (2.4628 - 2.4634) Measure 15 (0.6) from the skirt end.

62.480 (2.4598)

Cylinder distortion

0.20 (0.008)

Piston ring free end gap

1st

R

Approx. (06276)

5.4 (0.21)

2nd

RN

Approx.

5.6 (0.22)

Piston ring end gap

1st

0.1 - 0.3 (0.004 - 0.012)

0.5 (0.02)

2nd

0.3 - 0.5 (0.012 - 0.020)

0.7 (0.03)

ITEM

STANDARD

LIMIT

Piston-ring to piston-ring-groove clearance

1st

0.180 (0.007)

(0.006)

Piston ring groove width

1st

1.02 - 1.04 (0.040 - 0.041)

2nd

0.81 - 0.83 (0.032 - 0.033)

Oil

1.51 - 1.53 (0.059 - 0.060)

Piston ring thickness

1st

0.97 - 0.99 (0.038 - 0.039)

2nd

0.77 - 0.79 (0.030 - 0.031)

Piston pin bore

18.002 - 18.008 (0.7087 - 0.7090)

18.030 (0.7098)

Piston pin O.D.

17.996 - 18.000 (0.7085 - 0.7086)

17.980 (0.7079)

CONROD + CRANKSHAFT

Unit: mm (in)

ITEM

STANDARD

LIMIT

Conrod small end I.D.

18.010 - 18.018 (0.7091 - 0.7094)

18.040 (0.7102)

Conrod big end side clearance

0.10 - 0.20 (0.004 - 0.008)

0.30 (0.01)

Conrod big end width

20.95 - 21.00 (0.825 - 0.827)

Crank pin width

21.10 - 21.15 (0.831 - 0.833)

Conrod big end oil clearance

0.032 - 0.056 (0.0013 - 0.0022)

0.080 (0.0031)

Crank pin O.D.

33.976 - 34.000 (1.3376 - 1.3386)

Crankshaft journal oil clearance

0.020 - 0.044 (0.0008 - 0.0017)

0.080 (0.0031)

Crankshaft journal O.D.

31.976 - 32.000 (1.2589 - 1.2598)

Crankshaft thrust clearance

0.04 - 0.09 (0.002 - 0.004)

Crankshaft thrust bearing thickness

Left side

2.350 - 2.500 (0.0925 - 0.0984)

Right side

2.425 - 2.450 (0.0955 - 0.0965)

Crankshaft runout

0.05 (0.002)

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