Loading...
EAS00000
FZS1000 (N)
SERVICE MANUAL2000 by Yamaha Motor Co.Ltd.
First edition, December 2000
All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
EAS00003
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools in necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully.
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
|
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR |
|||
|
SAFETY IS INVOLVED! |
|||
|
Failure to follow WARNING instructions could result in severe injury or death to |
|||
|
the motorcycle operator, a bystander or |
|
|
|
|
a person checking or repairing the mo- |
|||
|
torcycle. |
|||
|
A CAUTION indicates special precautions that must be taken to avoid damage |
|||
CAUTION: |
||||
|
to the motorcycle. |
|||
NOTE: |
||||
A NOTE provides key information to make procedures easier or clearer. |
||||
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to ªSYMBOLSº on the following page.
2Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (ªPeriodic Checks and Adjustmentsº), where the sub-section title(-s) appears.
(In Chapter 3, ªPeriodic Checks and Adjustmentsº, the sub-section title appears at the top of each page, instead of the section title.)
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.
6Symbols indicate parts to be lubricated or replaced (see ªSYMBOLSº).
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequentially.
6 |
2 |
1 |
|
|
3 |
4 |
|
|
5 |
|
|
|
|
8 |
7 |
|
|
1 |
2 |
GEN |
SPEC |
|
INFO |
||
|
||
3 |
4 |
|
CHK |
CHAS |
|
ADJ |
||
|
||
5 |
6 |
|
ENG |
COOL |
|
7 |
8 |
|
CARB |
ELEC |
|
9 |
10 |
|
TRBL |
|
|
SHTG |
|
|
11 |
12 |
13 |
14 |
15 |
16 |
17 |
18 |
19 |
20 |
21 |
22 |
23 |
24 |
25 |
EAS00008
SYMBOLS
The following symbols are not relevant to every vehicle.
Symbols 1 to 9 indicate the subject of each chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Carburetor(-s)
8Electrical system
9Troubleshooting
Symbols 10 to 17 indicate the following.
10Serviceable with engine mounted
11Filling fluid
12Lubricant
13Special tool
14Tightening torque
15Wear limit, clearance
16Engine speed
17Electrical data
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
18Engine oil
19Gear oil
20Molybdenum disulfide oil
21Wheel bearing grease
22Lithium soap base grease
23Molybdenum disulfide grease
Symbols 24 to 25 in the exploded diagrams indicate the following:
24Apply locking agent (LOCTITER)
25Replace the part
EAS00012
TABLE OF CONTENTS
GENERAL INFORMATION |
|
|
|
|
|
|
GEN |
1 |
|||
|
|
INFO |
|||
|
|
|
|
|
|
SPECIFICATIONS |
|
|
|
|
|
|
SPEC |
2 |
|||
|
|
||||
|
|
|
|
|
|
PERIODIC CHECKS AND |
|
|
|
|
|
|
CHK |
3 |
|||
ADJUSTMENTS |
|
||||
|
ADJ |
|
|||
|
|
|
|
|
|
CHASSIS |
|
|
|
|
|
CHAS |
4 |
||||
|
|||||
|
|
|
|
|
|
ENGINE |
|
|
|
|
|
|
ENG |
5 |
|||
|
|
||||
|
|
|
|
|
|
COOLING SYSTEM |
|
|
|
|
|
COOL |
6 |
||||
|
|||||
|
|
|
|
|
|
CARBURETORS |
|
|
|
|
|
CARB |
7 |
||||
|
|||||
|
|
|
|
|
|
ELECTRICAL SYSTEM |
|
|
|
|
|
|
ELEC |
8 |
|||
|
|
||||
|
|
|
|
|
|
TROUBLESHOOTING |
|
|
|
|
|
|
TRBL |
9 |
|||
|
|
SHTG |
|||
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . 1-2 REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . 1-2 BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
GEN INFO
GEN
MOTORCYCLE IDENTIFICATION INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped into the right side of the steering head.
EAS00018
MODEL CODE
The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
1-1
lip
lip spring
oil
GEN
IMPORTANT INFORMATION INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
1.Before removal and disassembly, remove all dirt, mud, dust and foreign material.
2.Use only the proper tools and cleaning equipment.
Refer to the ªSPECIAL TOOLSº section.
3.When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been ºmatedº through normal wear. Mated parts must always be reused or replaced as an assembly.
4.During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.
5.Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
1.Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1.When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.
2.During reassembly, properly oil all mating
grease |
parts and bearings and apply grease onto |
|
the oil seal lips with greace. |
EAS00023
LOCK WASHERS/PLATES AND COTTER PINS
1.After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.
1-2
IMPORTANT INFORMATION
EAS00024
GEN INFO
BEARINGS AND OIL SEALS
1.Install bearings and oil seals so that the manufacturer's marks or numbers are visible. When installing oil seals, apply a light coat of lithium soap base grease onto the oil seal lips. Oil bearings liberally when installing, if appropriate.
1 Oil seal
CAUTION:
Do not spin the bearing with compressed air because this will damage the bearing surfaces.
1 Bearing
EAS00025
CIRCLIPS
1.Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1 , make sure that the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives.
4 Shaft
1-3
GEN
CHECKING THE CONNECTIONS INFO
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for stains, rust, moisture, etc.
1.Disconnect:
lead 1
coupler 2
connector 3
2.Check:
lead
coupler
connector
Moisture Dry with an air blower. Rust/stains Connect and disconnect several times.
3.Check:
all connections
Loose connection Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it up.
4.Connect:
lead
coupler
connector
NOTE:
Make sure that all connections are tight.
5.Check:
continuity
(with a pocket tester)
Pocket tester 90890-03112
NOTE:
If there is no continuity, clean the terminals.
When checking the wire harness, perform steps 1 to 3.
As a quick remedy, use a contact revitalizer available at most part stores.
1-4
GEN
SPECIAL TOOLS INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. |
Tool name/Function |
Illustration |
Rotor puller
90890-01080 |
|
|
This tool is used to remove the generator |
|
rotor. |
|
|
|
Rotor holding tool |
90890-01235 |
This tool is used to hold the generator rotor |
|
when removing or installing the generator |
|
rotor bolt or pickup coil rotor bolt. |
|
|
|
Piston pin puller set |
90890-01304 |
|
|
This tool is used to remove the piston pins. |
|
|
|
Fuel level gauge |
90890-01312 |
|
|
This tool is used to measure the fuel level in |
|
the float chamber. |
|
|
Radiator cap |
Radiator cap tester |
tester |
Adapter |
90890-01325 |
|
Adapter |
These tools are used to check the cooling |
90890-01352 |
system. |
|
|
|
Steering nut wrench |
90890-01403 |
|
|
This tool is used to loosen or tighten the |
|
steering stem ring nuts. |
|
|
|
Damper rod holder |
90890-01447 |
This tool is used to hold the damper rod as- |
|
sembly when loosening or tightening the |
|
damper rod assembly bolt. |
1-5
|
SPECIAL TOOLS |
|
|
GEN |
|
|
|
|
|
INFO |
|
||
|
|
|
|
|||
Tool No. |
Tool name/Function |
|
Illustration |
|||
|
|
|
|
|
|
|
|
Oil filter wrench |
|
|
|
|
|
90890-01426 |
|
|
|
|
|
|
|
This tool is needed to loosen or tighten the |
|
|
|
|
|
|
oil filter cartridge. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Rod holder |
|
|
|
|
|
90890-01434 |
|
|
|
|
|
|
|
This tool is used to support the damper ad- |
|
|
|
|
|
|
justing rod. |
|
|
|
|
|
|
|
|
|
|
|
|
Rod puller |
Rod puller |
|
|
|
|
|
90890-01437 |
Rod puller attachment |
|
|
|
|
|
Rod puller |
|
|
|
|
|
|
attachment |
These tools are used to pull up the front |
|
|
|
|
|
90890-01436 |
fork damper rod. |
|
|
|
|
|
|
|
|
|
|
|
|
Fork seal driver |
Fork seal driver weight |
|
|
|
|
|
weight |
Fork seal driver attachment (ù43) |
|
|
|
|
|
90890-01367 |
|
|
|
|
|
|
Fork seal driver |
This tool is used to install the front fork's oil |
|
|
|
|
|
attachment (ù43) |
|
|
|
|
|
|
seal and dust seal. |
|
|
|
|
|
|
90890-01374 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Micrometer (50 75 mm) |
|
|
|
|
|
90890-03008 |
|
|
|
|
|
|
|
This tool is used to measure the piston skirt |
|
|
|
|
|
|
diameter. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Vacuum gauge |
|
|
|
|
|
Vacuum gauge |
|
|
|
|
|
|
90890-03094 |
This guide is used to synchronize the car- |
|
|
|
|
|
|
|
|
|
|
|
|
|
buretors. |
|
|
|
|
|
|
|
|
|
|
|
|
Compression |
Compression gauge |
|
|
|
|
|
gauge |
Compression gauge adapter |
|
|
|
|
|
90890-03081 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Compression |
These tools are used to measure engine |
|
|
|
|
|
gauge adapter |
|
|
|
|
|
|
compression. |
|
|
|
|
|
|
90890-04136 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pocket tester |
|
|
|
|
|
90890-03112 |
|
|
|
|
|
|
|
This tool is used to check the electrical sys- |
|
|
|
|
|
|
tem. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Engine tachometer |
|
|
|
|
|
90890-03113 |
|
|
|
|
|
|
|
This tool is used to check engine speed. |
|
|
|
|
|
|
|
|
|
|
|
|
1-6
|
SPECIAL TOOLS |
|
|
GEN |
|
|
|
|
|
INFO |
|
||
|
|
|
|
|||
Tool No. |
Tool name/Function |
|
Illustration |
|||
|
|
|
|
|
|
|
|
Timing light |
|
|
|
|
|
90890-03141 |
|
|
|
|
|
|
|
This tool is used to check the ignition tim- |
|
|
|
|
|
|
ing. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Carburetor angle driver 2 |
|
|
|
|
|
90890-03173 |
|
|
|
|
|
|
|
This tool is used to turn the pilot screw |
|
|
|
|
|
|
when adjusting the engine idling speed. |
|
|
|
|
|
|
|
|
|
|
|
|
Valve spring com- |
Valve spring compressor |
|
|
|
|
|
pressor |
Valve spring compressor attachment |
|
|
|
|
|
90890-04019 |
|
|
|
|
|
|
Attachmenht |
These tools are used to remove or install |
|
|
|
|
|
90890-04108 |
|
|
|
|
|
|
the valve assemblies. |
|
|
|
|
|
|
90890-04114 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Middle driven shaft |
Middle driven shaft bearing driver |
|
|
|
|
|
bearing driver |
Mechanical seal installer |
|
|
|
|
|
90890-04058 |
|
|
|
|
|
|
Mechanical seal |
These tools are used to install the water |
|
|
|
|
|
installer |
|
|
|
|
|
|
pump seal. |
|
|
|
|
|
|
90890-04078 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Universal clutch holder |
|
|
|
|
|
90890-04086 |
This tool is used to hold the clutch boss |
|
|
|
|
|
|
when removing or installing the clutch boss |
|
|
|
|
|
|
nut. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Valve guide remover (ù4) |
|
|
|
|
|
90890-04111 |
Valve guide remover (ù4.5) |
|
|
|
|
|
|
|
|
|
|
|
|
90890-04116 |
This tool is used to remove or install the |
|
|
|
|
|
|
|
|
|
|
|
|
|
valve guides. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Valve guide installer (ù4) |
|
|
|
|
|
90890-04112 |
Valve guide installer (ù4.5) |
|
|
|
|
|
|
|
|
|
|
|
|
90890-04117 |
|
|
|
|
|
|
|
This tool is used to install the valve guides. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Valve guide reamer (ù4) |
|
|
|
|
|
90890-04113 |
Valve guide reamer (ù4.5) |
|
|
|
|
|
|
|
|
|
|
|
|
90890-04118 |
This tool is used to rebore the new valve |
|
|
|
|
|
|
|
|
|
|
|
|
|
guides. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Ignition checker |
|
|
|
|
|
90890-06754 |
|
|
|
|
|
|
|
This tool is used to check the ignition sys- |
|
|
|
|
|
|
tem components. |
|
|
|
|
|
|
|
|
|
|
|
|
1-7
|
SPECIAL TOOLS |
|
|
GEN |
|
|
|
|
|
INFO |
|
||
|
|
|
|
|||
Tool No. |
Tool name/Function |
|
Illustration |
|||
|
|
|
|
|
|
|
|
Yamaha bond No. 1215 |
|
|
|
|
|
90890-85505 |
|
|
|
|
|
|
|
This bond is used to seal two mating sur- |
|
|
|
|
|
|
faces (e.g., crankcase mating surfaces). |
|
|
|
|
|
|
|
|
|
|
|
|
1-8
SPEC 
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 GENERAL TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-23 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
COOLING SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
ENGINE OIL LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
SPEC 
|
GENERAL SPECIFICATIONS |
|
SPEC |
|
||
SPECIFICATIONS |
|
|
|
|
||
|
|
|
|
|||
GENERAL SPECIFICATIONS |
|
|
|
|
|
|
|
|
|
|
|
|
|
Item |
|
Standard |
|
|
Limit |
|
|
|
|
|
|||
Model code |
|
5VL1 (A) (B) (D) (DK) (E) (GB) (GR) (I) |
|
|||
|
|
(N) (NL) (S) (SF) (CH) (P) |
|
|
|
|
|
|
5LV2 (F) |
|
|
|
|
|
|
5LV3 (D) |
|
|
|
|
|
|
5LV4 (AUS) |
|
|
|
|
|
|
|
|
|
|
|
Dimensions |
|
|
|
|
|
|
Overall length |
|
2,125 mm |
|
|
|
|
Overall width |
|
765 mm |
|
|
|
|
Overall height |
|
1,190 mm |
|
|
|
|
Seat height |
|
820 mm |
|
|
|
|
Wheelbase |
|
1,450 mm |
|
|
|
|
Minimum ground clearance |
|
140 mm |
|
|
|
|
Minimum turning radius |
|
2,900 mm |
|
|
|
|
|
|
|
|
|
|
|
Weight |
|
|
|
|
|
|
Wet (with oil and a full fuel tank) |
|
231 kg |
|
|
|
|
Dry (without oil and fuel) |
|
208 kg |
|
|
|
|
Maximum load (total of cargo, rider, |
|
189 kg |
|
|
|
|
passenger, and accessories) |
|
|
|
|
|
|
|
|
|
|
|
|
|
2-1
|
ENGINE SPECIFICATIONS |
|
SPEC |
|
|
ENGINE SPECIFICATIONS |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Item |
Standard |
|
|
Limit |
|
|
|
|
|
|
|
Engine |
|
|
|
|
|
Engine type |
Liquid-cooled, 4-stroke, DOHC |
|
|
|
|
Displacement |
998 cm3 |
|
|
|
|
Cylinder arrangement |
Forward-inclined parallel 4-cylinder |
|
|
|
|
Bore stroke |
74 58 mm |
|
|
|
|
Compression ratio |
11.4 : 1 |
|
|
|
|
Engine idling speed |
1,050 1,150 r/min |
|
|
|
|
Vacuum pressure at engine idling |
30 kPa (225 mm Hg) |
|
|
|
|
speed |
1,450 kPa (14.5 kg/cm2) at 400 r/min |
|
|
||
Standard compression pressure |
|
|
|||
(at sea level) |
|
|
|
|
|
|
|
|
|
|
|
Fuel |
|
|
|
|
|
Recommended fuel |
Regular unleaded gasoline |
|
|
|
|
Fuel tank capacity |
|
|
|
|
|
Total (including reserve) |
21 L |
|
|
|
|
Reserve only |
4.0 L |
|
|
|
|
|
|
|
|
|
|
Engine oil |
|
|
|
|
|
Lubrication system |
Wet sump |
|
|
|
|
Recommended oil |
|
|
|
|
|
|
SAE20W40SE or SAE10W30SE |
|
|
|
|
Quantity |
|
|
Total amount |
3.7 L |
|
Without oil filter cartridge |
2.8 L |
|
replacement |
|
|
With oil filter cartridge replacement |
3.0 L |
|
Oil pressure (hot) |
45 kPa at 1,100 r/min |
|
|
(0.45 kg/cm2 at 1,100 r/min) |
|
Relief valve opening pressure |
490 570 kPa (4.9 5.7 kg/cm2) |
|
2-2
|
ENGINE SPECIFICATIONS |
|
SPEC |
|
||
|
|
|
|
|
|
|
|
|
|
|
|||
Item |
Standard |
|
Limit |
|||
|
|
|
|
|
|
|
Oil filter |
|
|
|
|
|
|
Oil filter type |
Cartridge (paper) |
|
|
|
||
Bypass valve opening pressure |
180 220 kPa (1.8 2.2 kg/cm2) |
|
|
|
||
Oil pump |
|
|
|
|
|
|
Oil pump type |
Trochoid |
|
|
|
||
Inner-rotor-to-outer-rotor-tip |
0.09 0.15 mm |
|
|
|
||
clearance |
|
|
|
|
|
|
Outer-rotor-to-oil-pump-housing |
0.03 0.08 mm |
|
|
|
||
clearance |
|
|
|
|
|
|
|
|
|
|
|
|
|
Cooling system |
|
|
|
|
|
|
Radiator capacity |
2.4 L |
|
|
|
||
Radiator cap opening pressure |
95 125 kPa (0.95 1.25 kg/cm2) |
|
|
|
||
Radiator core |
|
|
|
|
|
|
Width |
340 mm |
|
|
|
||
Height |
238 mm |
|
|
|
||
Depth |
24 mm |
|
|
|
||
Coolant reservoir |
|
|
|
|
|
|
Capacity |
0.3 L |
|
|
|
||
Water pump |
|
|
|
|
|
|
Water pump type |
Single-suction centrifugal pump |
|
|
|
||
Reduction ratio |
68/43 28/28 (1.581) |
|
|
|
|
|
Max. impeller shaft tilt |
|
|
|
|
0.15 mm |
|
|
|
|
|
|
||
Starting system type |
Electric starter |
|
|
|
||
|
|
|
|
|
|
|
Spark plugs |
|
|
|
|
|
|
Model (manufacturer) quantity |
CR9E/U27ESR-N (NGK/DENSO) 4 |
|
|
|||
Spark plug gap |
0.7 0.8 mm |
|
|
|
||
|
|
|
|
|
|
|
Cylinder head |
|
|
|
|
|
|
Max. warpage |
|
|
|
|
0.1 mm |
|
|
|
|
|
|
|
|
2-3
|
ENGINE SPECIFICATIONS |
|
SPEC |
|
|
|
|
|
|
|
|
|
|
|
Item |
Standard |
|
Limit |
|
|
|
|
|
|
Camshafts |
|
|
|
|
Drive system |
Chain drive (right) |
|
|
|
Camshaft cap inside diameter |
24.500 X 24.521 mm |
|
|
|
Camshaft journal diameter |
24.459 X 24.472 mm |
|
|
|
Camshaft-journal-to-camshaft- |
0.028 X 0.062 mm |
|
|
|
cap clearance |
|
|
|
|
Intake camshaft lobe dimensions |
|
|
|
|
Measurement A |
32.5 X 32.6 mm |
32.4 mm |
Measurement B |
24.95 X 25.05 mm |
24.85 mm |
Measurement C |
7.45 X 7.65 mm |
|
Exhaust camshaft lobe dimensions
Measurement A |
32.95 X 33.05 mm |
32.85 mm |
Measurement B |
24.95 X 25.05 mm |
24.85 mm |
Measurement C |
7.75 X 7.95 mm |
|
Max. camshaft runout |
|
0.03 mm |
2-4
|
ENGINE SPECIFICATIONS |
|
SPEC |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Item |
Standard |
|
|
Limit |
|
|
|
|
|
|
|
Timing chain |
|
|
|
|
|
Model/number of links |
RH2015/130 |
|
|
|
|
Tensioning system |
Automatic |
|
|
|
|
|
|
|
|
|
|
Valves, valve seats, valve guides |
|
|
|
|
|
Valve clearance (cold) |
|
|
|
|
|
Intake |
0.11 X 0.20 mm |
|
|
|
|
Exhaust |
0.21 X 0.25 mm |
|
|
|
|
Valve dimensions |
|
|
|
|
|
|
|
|
|
|
|
Head Diameter |
Face Width |
Seat Width |
Margin Thickness |
Valve head diameter A |
|
|
|
Intake |
|
22.9 X 23.1 mm |
|
Exhaust |
|
24.4 X 24.6 mm |
|
Valve face width B |
|
|
|
Intake |
|
1.76 X 2.90 mm |
|
Exhaust |
|
1.76 X 2.90 mm |
|
Valve seat width C |
|
|
|
Intake |
|
0.9 X 1.1 mm |
|
Exhaust |
|
0.9 X 1.1 mm |
|
Valve margin thickness D |
|
|
|
Intake |
|
0.5 X 0.9 mm |
|
Exhaust |
|
0.5 X 0.9 mm |
|
Valve stem diameter |
|
|
|
Intake |
|
3.975 X 3.990 mm |
3.945 mm |
Exhaust |
|
4.465 X 4.480 mm |
4.43 mm |
Valve guide inside diameter |
|
|
|
Intake |
|
4.000 X 4.012 mm |
4.05 mm |
Exhaust |
|
4.500 X 4.512 mm |
4.55 mm |
Valve-stem-to-valve-guide clearance |
|
|
|
Intake |
|
0.010 X 0.037 mm |
0.08 mm |
Exhaust |
|
0.020 X 0.047 mm |
0.10 mm |
Valve stem runout |
|
|
0.01 mm |
Valve seat width |
|
|
Intake |
0.9 X 1.1 mm |
|
Exhaust |
0.9 X 1.1 mm |
|
2-5
|
ENGINE SPECIFICATIONS |
|
SPEC |
|
|
|
|
|
|
|
|
|
|
|
Item |
Standard |
|
Limit |
|
|
|
|
|
|
Valve springs |
|
|
|
|
Free length |
|
|
|
|
Intake |
38.9 mm |
|
|
|
Exhaust |
40.67 mm |
|
|
|
Installed length (valve closed) |
|
|
|
|
Intake |
34.5 mm |
|
|
|
Exhaust |
35 mm |
|
|
|
Compressed spring force |
|
|
|
|
(installed) |
|
|
|
|
Intake |
82 96 N (8.36 9.79 kg) |
|
|
|
Exhaust |
110 126 N (11.22 12.85 kg) |
|
|
|
Spring tilt |
|
|
|
|
Intake |
|
2.5_/ |
|
|
1.7 mm |
Exhaust |
|
2.5_/ |
|
|
1.8 mm |
Winding direction (top view) |
|
|
Intake |
Clockwise |
|
Exhaust |
Clockwise |
|
Cylinders |
|
|
Cylinder arrangement |
Forward-inclined, parallel 4-cylinder |
|
Bore stroke |
74 58 mm |
|
Compression ratio |
11.4 : 1 |
|
Bore |
74.00 74.01 mm |
|
Max. taper |
|
0.05 mm |
Max. out-of-round |
|
0.05 mm |
2-6
|
ENGINE SPECIFICATIONS |
|
SPEC |
|
|
|
|
|
|
|
|
|
|
|
Item |
Standard |
|
Limit |
|
|
|
|
|
|
Piston |
|
|
|
|
Piston-to-cylinder clearance |
0.030 0.055 mm |
|
0.12 mm |
|
Diameter D |
73.955 73.970 mm |
|
|
|
Height H |
5 mm |
|
Piston pin bore (in the piston) |
|
|
Diameter |
17.002 17.013 mm |
17.043 |
Offset |
|
|
Offset direction |
Intake side |
|
Piston pins |
|
|
Outside diameter |
16.991 17.000 mm |
16.971 |
Piston-pin-to-piston-pin-bore |
0.002 0.022 mm |
0.072 mm |
clearance |
|
|
Piston rings |
|
|
Top ring |
|
|
Ring type |
Barrel |
|
Dimensions (B T) |
0.90 2.75 mm |
|
End gap (installed) |
0.32 0.44 mm |
|
Ring side clearance |
0.030 0.065 mm |
|
2nd ring
Ring type |
Taper |
|
Dimensions (B T) |
0.8 2.8 |
|
End gap (installed) |
0.43 0.58 mm |
|
Ring side clearance |
0.020 0.055 mm |
|
Oil ring
Dimensions (B T) |
1.5 2.6 mm |
|
End gap (installed) |
0.10 0.35 |
|
2-7
|
ENGINE SPECIFICATIONS |
|
SPEC |
|
|
|
|
|
|
|
|
|
|
|
Item |
Standard |
|
Limit |
|
|
|
|
|
|
Connecting rods |
|
|
|
|
Crankshaft-pin-to-big-end-bearing |
0.031 X 0.055 mm |
|
|
|
clearance |
|
|
|
|
Bearing color code |
±1 = Violet 0 = White 1 = Blue 2 = Black |
|||
Crankshaft |
|
|
|
|
Width A |
52.40 X 57.25 mm |
|
|
Width B |
300.75 X 302.65 mm |
|
|
Max. runout C |
|
0.03 mm |
|
Big end side clearance D |
0.160 X 0.262 mm |
|
|
Crankshaft-journal-to-crankshaft- |
0.029 X 0.053 mm |
|
|
journal-bearing clearance |
|
|
|
Bearing color code |
±1 = Pink/violet 0 = Pink/white |
|
|
|
1 |
= Pink/blue 2 = Pink/black |
|
|
3 |
= Pink/brown |
|
|
|
|
|
Clutch |
|
|
|
Clutch type |
Wet, multiple disc |
|
|
Clutch release method |
Cam (pull rod type) |
|
|
Clutch release method operation |
Cable operation |
|
|
Operation |
Left-hand operation |
|
|
Clutch cable free play (at the end |
10 X 15 mm |
|
|
of the clutch lever) |
|
|
|
Friction plates |
|
|
|
Thickness |
2.92 X 3.08 mm |
2.82 mm |
|
Plate quantity |
8 |
|
|
Thickness |
3.42 X 3.58 mm |
3.32 mm |
|
Plate quantity |
1 |
|
|
Clutch plates |
|
|
|
Thickness |
1.9 X 2.1 mm |
|
|
Plate quantity |
8 |
|
|
Max. warpage |
|
0.1 mm |
|
Clutch springs |
|
|
|
Free length |
50 mm |
|
|
Spring quantity |
6 |
|
|
2-8
Loading...