Valves, guides and springs

Valve clearances................................................................................. see Chapter 1

Inlet valve

Stem diameter

Standard....................................................................................... 4.475 to 4.490 mm

Service limit (min) ...................................................................... 4.465 mm

Guide bore diameter

Standard....................................................................................... 4.500 to 4.412 mm

Service limit (max)........................................................................ 4.562 mm

Stem-to-guide clearance

Standard....................................................................................... 0.010 to 0.037 mm

Service limit (max)........................................................................ Not available

Seat width

Standard....................................................................................... 1.0 mm

Service limit.................................................................................. 1.5 mm

Valve guide height above cylinder head....................................... 15.30 to 15.50 mm

Exhaust valve

Stem diameter

Standard....................................................................................... 4.465 to 4.480 mm

Service limit (min) ...................................................................... 4.455 mm

Guide bore diameter

Standard....................................................................................... 4.500 to 4.512 mm

Service limit (max)........................................................................ 4.612 mm

Stem-to-guide clearance

Standard....................................................................................... 0.020 to 0.047 mm

Service limit (max)........................................................................ Not available

Seat width

Standard....................................................................................... 1.0 mm

Service limit................................................................................... 1.5 mm

Valve guide height above cylinder head....................................... 15.30 to 15.50 mm

Valve springs free length (inlet and exhaust)

Standard....................................................................................... 37.86 mm

Service limit (min) ...................................................................... 36.1 mm

Clutch

No. of friction plates............................................................................ 7

No. of plain plates............................................................................... 6

Friction plate thickness

Standard........................................................................................... 2.92 to 3.08 mm

Service limit (min) .......................................................................... 2.60 mm

Plain plate warpage (max) ............................................................... 0.3 mm

Spring free height

Standard........................................................................................... 43.2 mm

Service limit (min) ................................................................................ 42.0 mm

Clutch housing sleeve outside diameter

Standard................................................................................................ 29.993 to 30.007 mm

Service limit (min) ................................................................................ 29.96 mm

Clutch housing sleeve inside diameter

Standard........................................................................................... 21.980 to 21.993 mm

Service limit (max)............................................................................ 22.03 mm

Transmission input shaft outside diameter at sleeve point

Standard........................................................................................... 21.967 to 21.980 mm

Service limit (max)............................................................................ 21.950 mm

Engine, clutch and transmission 2«3

Lubrication system

Oil pressure........................................................................................ see Chapter 1

Oil pump Inner rotor tip-to-outer rotor clearance

Standard....................................................................................... 0.15 mm

Service limit (max)....................................................................... not available

Outer rotor-to-body clearance

Standard....................................................................................... 0.15 to 0.21 mm

Service limit (max)....................................................................... not available

Rotor end-float

Standard....................................................................................... 0.02 to 0.09 mm

Service limit (max)....................................................................... not available

Cylinder bores

Bore

Standard............................................................................................... 73.000 to 73.015 mm

Service limit (max)............................................................................... 73.10 mm

Warpage (max)............................................................................................ 0.10 mm

Ovality (out-of-round) (max) ............................................................ 0.10 mm

Taper (max)................................................................................................. 0.10 mm

Cylinder compression........................................................................... see Chapter 1

Connecting rods

Small-end inside diameter

Standard.......................................................................................... 17.016 to 17.034 mm

Service limit (max).......................................................................... 17.07 mm

Small-end-to-piston pin clearance

Standard.......................................................................................... 0.016 to 0.040 mm

Service limit (max).......................................................................... Not available

Big-end side clearance

Standard.......................................................................................... 0.06 to 0.10 mm

Service limit (max).......................................................................... 0.30 mm

Big-end oil clearance

Standard.......................................................................................... 0.030 to 0.052 mm

Service limit (max).......................................................................... 0.06 mm

Pistons

Piston diameter (measured at 90° to piston pin axis)

Standard.......................................................................................... 72.970 to 72.990 mm

Service limit (min) ......................................................................... 72.90 mm

Piston-to-bore clearance

Standard.......................................................................................... 0.010 to 0.045 mm

Service limit (max)........................................................................... Not available

Piston pin diameter

Standard.......................................................................................... 16.994 to 17.000 mm

Service limit (min) ......................................................................... 16.98 mm

Piston pin bore diameter in piston

Standard.......................................................................................... 17.002 to 17.008 mm 2

Service limit (max).......................................................................... 17.02 mm

Piston pin-to-piston pin bore clearance

Standard.......................................................................................... 0.002 to 0.014 mm

Service limit (max).......................................................................... Not available

Piston rings

Ring end gap (installed) Top ring

Standard....................................................................................... 0.15 to 0.30 mm

Service limit (max)....................................................................... 0.50 mm

2nd ring

Standard....................................................................................... 0.30 to 0.45 mm

Service limit (max)....................................................................... 0.60 mm

Oil ring side-rail

Standard....................................................................................... 0.20 to 0.70 mm

Service limit (max)....................................................................... 1.00 mm

Ring-to-groove clearance Top ring

Standard....................................................................................... 0.025 to 0.060 mm

Service limit (max)....................................................................... 0.08 mm

2nd ring

Standard....................................................................................... 0.015 to 0.050 mm

Service limit (max)....................................................................... 0.08 mm

2»4 Engine, clutch and transmission

Crankshaft and bearings

Main bearing oil clearance

Standard................................................................................................ 0.026 to 0.044 mm

Service limit (max)................................................................................ 0.05 mm

Runout (max) ......................................................................................... 0.05 mm

Transmission

Gear ratios (No. of teeth)

Primary reduction................................................................................. 1.947 to 1 (74/38T)

1st gear................................................................................................. 3.461 to 1 (45/13T)

2nd gear................................................................................................ 2.235 to 1 (38/177)

3rd gear................................................................................................. 1.750 to 1 (35/20T)

4th gear................................................................................................. 1.478 to 1 (34/23T)

5th gear................................................................................................. 1.280 to 1 (32/25T)

6th gear................................................................................................. 1.130 to 1 (26/23T)

Final reduction ............................................................................... 2.666 to 1 (40/15T)

Input shaft 5th and 6th gears inside diameter

Standard................................................................................................ 28.000 to 28.021 mm

Service limit (max)............................................................................ 28.04 mm

Input shaft 5th and 6th gears, bush outside diameter

Standard........................................................................................... 27.959 to 27.980 mm

Service limit (min) ........................................................................... 27.94 mm

Input shaft 5th and 6th gears gear-to-bush clearance

Standard........................................................................................... 0.020 to 0.062 mm

Service limit (max)............................................................................ not available

Input shaft 5th gear bush inside diameter

Standard........................................................................................... 24.985 to 25.006 mm

Service limit (max)............................................................................ 25.016 mm

Input shaft outside diameter at 5th gear bush point

Standard........................................................................................... 24.967 to 24.980 mm

Service limit (min) .......................................................................... 24.960 mm

Input shaft-to-bush clearance at 5th gear bush point

Standard........................................................................................... 0.005 to 0.039 mm

Service limit (max)............................................................................ not available

Output shaft 1st gear inside diameter

Standard........................................................................................... 24.000 to 24.021 mm

Service limit (max)............................................................................ 24.04 mm

Output shaft 2nd, 3rd and 4th gears inside diameter

Standard................................................................................................ 31.000 to 31.021 mm

Service limit (max)............................................................................ 31.04 mm

Output shaft 2nd gear bush outside diameter

Standard........................................................................................... 30.955 to 30.980 mm

Service limit (min) ............................................................................... 30.94 mm

Output shaft 3rd and 4th gears bush outside diameter

Standard........................................................................................... 30.950 to 30.975 mm

Service limit (min) ................................................................................ 30.93 mm

Output shaft 2nd gear, gear-to-bush clearance

Standard........................................................................................... 0.020 to 0.070 mm

Service limit (max)............................................................................ not available

Output shaft 2nd gear bush inside diameter

Standard........................................................................................... 27.985 to 28.006 mm

Service limit (max)............................................................................ 28.021 mm

Output shaft outside diameter at 2nd gear bush point

Standard................................................................................................ 27.967 to 27.980 mm

Service limit (min) ................................................................................ 27.960 mm

Output shaft-to-bush clearance at 2nd gear bush point

Standard........................................................................................... 0.005 to 0.039 mm

Service limit (max)................................................................................ not available

Date: 2016-01-14; view: 1328