YAMAHA YFM400FWA(M) 2000 SERVICE MANUAL

SERVICE MANUAL

YFM400FWA

(

)

5GH3-AE1

2000

YFM400FWA(M) 2000

SERVICE MANUAL



1999 by Yamaha Motor Co., Ltd.

First Edition, July 1999

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone who uses this book to perform mainte-

nance and repairs on Yamaha machine has a basic understanding of the mechanical ideas

and the procedures of machine repair. Repairs attempted by anyone without this knowledge

are likely to render the machine unsafe and unfit for use.

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.

OTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

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 machine operator, a bystander or a person inspecting or

repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid

damage to the machine.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated sym-

bols”)

1st title

: This is the title of the chapter with its symbol in the upper right corner of each

page.

2nd title

: This title indicates the section of the chapter and only appears on the first page of

each section. It is located in the upper left corner of the page.

3rd title

: This title indicates a sub-section that is followed by step-by-step procedures

accompanied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

1. An easy-to-see exploded diagram

is provided for removal and disassembly jobs.

2. Numbers

are given in the order of the jobs in the exploded diagram. A number that is

enclosed by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol

marks

. The meanings of the symbol marks are given on the next page.

4. A job instruction chart

accompanies the exploded diagram, providing the order of jobs,

names of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements

are given in

addition to the exploded diagram and the job instruction chart.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols

are printed on

the top right of each page and indicate the

subject of each chapter.

General information

Specifications

Periodic inspections and adjustments

Engine

Cooling system

Carburetion

Drive train

Chassis

Electrical

Troubleshooting

Illustrated symbols

are used to

identify the specifications appearing in the

text.

Can be serviced with engine mounted

Filling fluid

Lubricant

Special tool

Torque

Wear limit, clearance

Engine speed

Ω

, V, A

Illustrated symbols

in the exploded

diagrams indicate the types of lubricants

and lubrication points.

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply wheel bearing grease

Apply lightweight lithium-soap base grease

Apply molybdenum disulfide grease

Illustrated symbols

O to P in the exploded

diagrams indicate where to apply a locking

agent O and when to install a new part P.

O Apply the locking agent (LOCTITE



)

P Replace

IJK

LMN

O P

GEN

INFO

SPEC

INSP

ADJ

ENG

COOL

CARB

DRIV

CHAS

–+

ELEC

TRBL

SHTG

New

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

SPEC

PERIODIC INSPECTION AND

ADJUSTMENTS

ENGINE

ENG

COOLING SYSTEM

COOL

CARBURETION

CARB

DRIVE TRAIN

DRIV

CHASSIS

CHAS

ELECTRICAL

ELEC

TROUBLESHOOTING

GEN

INFO

INSP

ADJ

–+

TRBL

SHTG

GEN

INFO

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MACHINE IDENTIFICATION

.........................................................................1-1

VEHICLE IDENTIFICATION NUMBER ..................................................1-1

MODEL LABEL ......................................................................................1-1

FEATURES

....................................................................................................1-2

LIQUID COOLING ENGINE ...................................................................1-2

PARK POSITION ...................................................................................1-2

IMPORTANT INFORMATION

.......................................................................1-3

PREPARATION FOR REMOVAL PROCEDURES .................................1-3

REPLACEMENT PARTS ........................................................................1-3

GASKETS, OIL SEALS AND O-RINGS ................................................1-3

LOCK WASHERS/PLATES AND COTTER PINS ..................................1-4

BEARINGS AND OIL SEALS ................................................................1-4

CIRCLIPS ...............................................................................................1-4

CHECKING OF CONNECTIONS

...................................................................1-5

SPECIAL TOOLS

...........................................................................................1-6

GEN

INFO

1 - 1

GEN

INFO

MACHINE IDENTIFICATION

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number

stamped into the left side of the frame.

MODEL LABEL

The model label

is affixed to the frame.

This information will be needed to order

spare parts.

1 - 2

GEN

INFO

FEATURES

LIQUID COOLING ENGINE

Compact liquid cooled 45˚ inclined engine.

A liquid cooling system has been incorpo-

rated for stable power and engine endur-

ance.

Radiator

Thermo switch

Fan motor

PARK POSITION

When the drive select lever is shifted into

the park position, a stopper lever is

engaged into the stopper gear preventing

the drive select lever and transmission from

moving.

When the drive select lever is at the “L”,

“H”, “N”, or “R” positions, the stopper

lever end

is moved away from the stop-

per gear

by the return spring

When the drive select lever is in the “P”

position, the lever cam

at the side of the

shift cam

lifts the stopper lever end

and the stopper lever end locks the drive

axle

When the stopper lever end

is not syn-

chronized, a torsion spring

retains the

rotation force of the shift cam

until it is

synchronized.

FEATURES

1 - 3

GEN

INFO

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL

PROCEDURES

1.Remove all dirt, mud, dust and foreign

material before removal and disassembly.

2.Use proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS” section.

3.When disassembling the machine, always

keep mated parts together. This includes

gears, cylinder, piston and other parts that

have been “mated” through normal wear.

Mated parts must always be reused or

replaced as an assembly.

4.During machine disassembly, clean all

parts and place them in trays in the order

of disassembly. This will speed up assem-

bly and allow for the correct installation of

all parts.

5.Keep all parts away from any source of

fire.

EB101010

REPLACEMENT PARTS

1.Use only genuine Yamaha parts for all

replacements. Use oil and grease recom-

mended by Yamaha for all lubrication

jobs. Other brands may be similar in func-

tion and appearance, but inferior in qual-

ity.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1.Replace all gaskets, seals and O-rings

when overhauling the engine. All gasket

surfaces, oil seal lips and O-rings must be

cleaned.

2.Properly oil all mating parts and bearings

during reassembly. Apply grease to the oil

seal lips.

IMPORTANT INFORMATION

GEN

INFO

1 - 4

EB101030

LOCK WASHERS/PLATES AND COTTER

PINS

1.Replace all lock washers/plates

and cot-

ter pins after removal. Bend lock tabs

along the bolt or nut flats after the bolt or

nut has been tightened to specification.

EB101040

BEARINGS AND OIL SEALS

1.Install bearings and oil seals so that the

manufacturer’s marks or numbers are vis-

ible. When installing oil seals, apply a

light coating of lightweight lithium base

grease to the seal lips. Oil bearings liber-

ally when installing, if appropriate.

Oil seal

CAUTION:

Do not use compressed air to spin the bear-

ings dry. This will damage the bearing sur-

faces.

Bearing

EB101050

CIRCLIPS

1.Check all circlips carefully before reas-

sembly. Always replace piston pin clips

after one use. Replace distorted circlips.

When installing a circlip

, make sure

that the sharp-edged corner

is posi-

tioned opposite the thrust

it receives.

See sectional view.

Shaft

IMPORTANT INFORMATION

1 - 5

GEN

INFO

CHECKING OF CONNECTIONS

EB801000

CHECKING OF CONNECTIONS

Check the connectors for stains, rust, mois-

ture, etc.

1.Disconnect:

●

Connector

2.Check:

●

Connector

Moisture

→

Dry each terminal with an air

blower.

Stains/rust

→

Connect and disconnect the

terminals several times.

3.Check:

●

Connector leads

Looseness

→

Bend up the pin

and con-

nect the terminals.

4.Connect:

●

Connector terminals

OTE:

The two terminals “click” together.

5.Check:

●

Continuity (using a pocket tester)

OTE:

●

If there is no continuity, clean the termi-

nals.

●

When checking the wire harness be sure

to perform steps 1 to 3.

●

As a quick remedy, use a contact revital-

izer available at most part stores.

●

Check the connector with a pocket tester

as shown.

GEN

INFO

1 - 6

SPECIAL TOOLS

EB102001

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly.

Use only the appropriate special tools; this will help prevent damage caused by the use of

inappropriate tools or improvised techniques. Special tools may differ by shape and part

number from country to country. In such a case, two types are provided.

When placing an order, refer to the list provided below to avoid any mistakes.

For US and CDN

P/N. YM-, YU-, YS-, YK-, ACC-

Except for US and CDN

P/N. 90890-

Tool No. Tool name/How to use Illustration

Bolt

90890-01083

Weight

90890-01084

Set

YU-01083-A

Slide hammer bolt (M6)/weight/set

These tools are used to remove the

rocker arm shaft.

90890-01135

YU-01135-A

Crankcase separating tool

This tool is used to separate the crank-

case.

90890-01225

YM-01225-A

Valve guide remover (7.0 mm)

This tool is needed to remove and

install the valve guide.

90890-04017

YM-04017

Valve guide installer (7.0 mm)

This tool is needed to install the valve

guide.

90890-01227

YM-01227

Valve guide reamer (7.0 mm)

This tool is needed to rebore the new

valve guide.

90890-01231

YM-01231

Gear lash measurement tool

This tool is used to measure the gear

lash.

90890-01235

YU-01235

Rotor holding tool

This tool is needed to hold the starter

puller when removing/installing the

starter puller bolt or camshaft sprocket

bolts.

GEN

INFO

1 - 7

SPECIAL TOOLS

Kit

90890-04088

Bolt

90890-01275

Buffer boss installer set

Crankshaft installer bolt

These tools are used to install the

crankshaft.

YU-90050

Crankshaft installer set

These tools are used to install the

crankshaft.

Adapter

YM-33279

Spacer

90890-04060

YM-90070-A

Adapter (#11)

Spacer (crankshaft installer)

These tools are used to install the

crankshaft.

90890-01304

YU-01304

Piston pin puller

This tool is used to remove the piston

pin.

90890-01311

YU-08035

Tappet adjusting tool (3 mm)

This tool is necessary for adjusting the

valve clearance.

90890-01312

YM-01312-A

Fuel level gauge

This gauge is used to measure the fuel

level in the float chamber.

90890-01325

YU-24460-01

Radiator cap tester

This tool is used to check the cooling

system.

90890-01352

YU-33984

Adapter

This tool is used to check the cooling

system.

90890-01348

Locknut wrench

This tool is needed when removing or

installing the secondary sheave

spring.

Tool No. Tool name/How to use Illustration

GEN

INFO

1 - 8

SPECIAL TOOLS

90890-04134

YM-04134

Sheave spring compressor

This tool is needed when removing or

installing the secondary sheave

spring.

90890-04135

YM-04135

Sheave fixed block

This tool is needed when removing or

installing the secondary sheave

spring.

90890-01404

YM-01404

Flywheel puller

These tools are needed to remove the

rotor.

90890-01327

YM-01327

Damper rod holder (30 mm)

This tool is needed to loosen and

tighten the steering stem bearing

retainer.

90890-01426

YU-38411

Oil filter wrench

This tool is needed to loosen or tighten

the oil filter cartridge.

90890-01430

YM-38404

Ring nut wrench

This tool is needed to removing and

installing the middle driven shaft bear-

ing retainer.

90890-01467

YM-01467

90890-01475

YM-01475

Gear lash measurement tool

This tool is used to measure the gear

lash.

90890-01701

YU-01880

Sheave holder

This tool is needed to hold the primary

sheave when removing or installing

the sheave bolts.

Set

90890-03081

YU-33223

Adapter

90890-04082

YU-33223-3

Compression gauge set

Adapter

These tools are needed to measure

engine compression.

Tool No. Tool name/How to use Illustration

GEN

INFO

1 - 9

SPECIAL TOOLS

90890-03112

YU-03112

Pocket tester

This instrument is needed for checking

the electrical system.

90890-03113

Engine tachometer

This tool is needed for observing

engine rpm.

YU-8036-A

Inductive tachometer

This tool is needed for observing

engine rpm.

90890-03141

YM-33277-A

Timing light

This tool is necessary for checking

ignition timing.

90890-04019

YM-04019

Valve spring compressor

This tool is needed to remove and

install the valve assemblies.

Middle driven shaft

bearing driver

90890-04058

YM-04058-1

Mechanical seal

installer

90890-04078

YM-33221

Middle driven shaft bearing driver

Mechanical seal installer

These tools are used to install the

water pump seal.

90890-04050

YM-04050

Bearing retainer wrench

This tool is needed when removing or

installing the final drive shaft bearing

retainer.

90890-04062

YM-04062

Universal joint holder

This tool is needed when removing or

installing the universal joint yoke nut.

90890-04086

YM-91042

Clutch holding tool

This tool is needed to hold the clutch

carrier when removing or installing the

carrier nut.

Tool No. Tool name/How to use Illustration

GEN

INFO

1 - 10

SPECIAL TOOLS

90890-04128

YM-04128

Bearing retainer wrench

This tool is needed when removing or

installing the middle driven pinion

gear bearing retainer.

90890-04129

YM-04129

Pinion gear fix clamp

This tool is used to hold the shift cam.

90890-06754

Ignition checker

This instrument is necessary for check-

ing the ignition system components.

YM-34487

Dynamic spark tester

This instrument is necessary for check-

ing the ignition system components.

Bond

90890-85505

Sealant

ACC-11001-05-01

Yamaha bond No. 1215

Sealant (Quick Gasket

)

This sealant (bond) is used on crank-

case mating surfaces, etc.

Tool No. Tool name/How to use Illustration

SPEC

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS

.........................................................................2-1

MAINTENANCE SPECIFICATIONS

...............................................................2-5

ENGINE ..................................................................................................2-5

CHASSIS ..............................................................................................2-15

ELECTRICAL .........................................................................................2-19

HOW TO USE THE CONVERSION TABLE

................................................2-21

GENERAL TORQUE SPECIFICATIONS

......................................................2-21

LUBRICATION POINTS AND LUBRICANT TYPES

...................................2-22

ENGINE ...............................................................................................2-22

COOLANT FLOW DIAGRAMS

...................................................................2-23

OIL FLOW DIAGRAMS

...............................................................................2-25

CABLE ROUTING

........................................................................................2-28

SPEC

2 - 1

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code: 5GH3 : (For CDN)

5GH4 : (For GB, F, CH)

5GH5 : (For Oceania)

Dimensions:

Overall length 1,965 mm (77.36 in)

Overall width 1,070 mm (42.13 in)

Overall height 1,120 mm (44.09 in)

Seat height 820 mm (32.28 in)

Wheelbase 1,225 mm (48.23 in)

Minimum ground clearance 245 mm (9.65 in)

Minimum turning radius 3,000 mm (118.11 in)

Basic weight:

With oil and full fuel tank 262 kg (578 lb)

Engine:

Engine type Liquid-cooled 4-stroke, SOHC

Cylinder arrangement Forward-inclined single cylinder

Displacement 401 cm

Bore

stroke 84.5

71.5 mm (3.33

2.81 in)

Compression ratio 10.5 : 1

Starting system Electric and recoil starter

Lubrication system: Wet sump

Oil type or grade:

Engine oil

API service SE, SF, SG type or higher

Final gear oil SAE 80API “GL-4” Hypoid Gear Oil

Differential gear oil SAE 80API “GL-4” Hypoid Gear Oil

Oil capacity:

Engine oil

Periodic oil change 2.3 L (2.0 lmp qt, 2.4 US qt)

With oil ﬁlter replacement 2.4 L (2.1 lmp qt, 2.5 US qt)

Total amount 2.6 L (2.3 lmp qt, 2.7 US qt)

Final gear case oil

Periodic oil change 0.19 L (0.17 lmp qt, 0.20 US qt)

Total amount 0.22 L (0.19 lmp qt, 0.23 US qt)

0° 10° 30° 50° 70° 90° 110°

YAMALUBE 4 (10W30) or SAE 10W30

-20° -10° 0° 10° 20° 30° 40°

YAMALUBE 4 (20W40) or SAE 20W40

SAE 5W30

130°F

50°C

GENERAL SPECIFICATIONS

2 - 2

SPEC

Differential gear case oil

Periodic oil change 0.35 L (0.31 lmp qt, 0.37 US qt)

Total amount 0.40 L (0.35 lmp qt, 0.42 US qt)

Radiator capacity (including all routes) 1.1 L (0.97 lmp qt, 1.16 US qt)

Air ﬁlter: Wet type element

Fuel:

Type

Regular unleaded gasoline (For CDN, GB, F, CH)

Unleaded fuel only (For Oceania)

Fuel tank capacity 15 L (3.3 lmp gal, 3.9 US gal)

Fuel reserve amount 4.5 L (0.99 lmp gal, 1.19 US gal)

Carburetor:

Type/quantity BSR33/1

Manufacturer MIKUNI

Spark plug:

Type/manufacturer DR8EA/NGK (For CDN, GB, F, CH)

D8EA/NGK (For Oceania)

X24ES-U/DENSO (For Oceania)

Spark plug gap 0.6 ~ 0.7 mm (0.02 ~ 0.03 in)

Clutch type: Wet, centrifugal automatic

Transmission:

Primary reduction system V-belt

Secondary reduction system Spur gear

Secondary reduction ratio 39/24

24/18

33/9 (7.944)

Transmission type V-belt automatic

Operation Left hand operation

Single speed automatic 2.55 ~ 0.75 : 1

Sub transmission ratio low 45/16 (2.813)

high 38/23 (1.652)

Reverse gear 29/17 (1.706)

Chassis:

Frame type Steel tube frame

Caster angle 4.0˚

Camber angle 1˚

Kingpin angle 11˚

Kingpin offset 1 mm (0.04 in)

Trail 21 mm (0.83 in)

Tread (STD) front 850 mm (33.46 in)

rear 825 mm (32.48 in)

Toe-in 0 ~ 10 mm (0 ~ 0.39 in)

Tire:

Type Tubeless

Size front AT25

8–12

rear AT25

10–12

Item Standard

GENERAL SPECIFICATIONS

2 - 3

SPEC

Manufacturer front DUNLOP (For CDN, GB, F, CH)

CHENG SHIN (For Oceania)

rear DUNLOP (For CDN, GB, F, CH)

CHENG SHIN (For Oceania)

Type front KT123 (For CDN, GB, F, CH)

C828 (For Oceania)

rear KT127 (For CDN, GB, F, CH)

C828 (For Oceania)

Item Standard

GENERAL SPECIFICATIONS

2 - 4

SPEC

Tire pressure (cold tire):

Maximum load* 210 kg (463 lb)

Off-road riding front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm

, 3.2 ~ 4.0 psi)

rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm

, 3.2 ~ 4.0 psi)

*Load in total weight of rider accessories

Brake:

Front brake type Dual disc brake

operation Right hand operation

Rear brake type Single disc brake

operation Left hand and right foot operation

Suspension:

Front suspension Double wishbone

Rear suspension Swingarm (monocross)

Shock absorber:

Front shock absorber Coil spring/oil damper

Rear shock absorber Coil spring/oil damper

Wheel travel:

Front wheel travel 160 mm (6.30 in)

Rear wheel travel 180 mm (7.09 in)

Electrical:

Ignition system C.D.I.

Generator system A.C. magneto

Battery type YTX20L-BS

Battery capacity 12 V 18 AH

Headlight type: Krypton bulb

Bulb wattage

quantity:

Headlight 12 V 30 W/30 W

Tail light 12 V 7.5 W

Meter light 14 V 3.4 W

Indicator lights

Neutral 14 V 1.7 W

Reverse 14 V 1.7 W

Coolant temperature 14 V 1.7 W

Four-wheel drive 14 V 1.7 W

Park 14 V 1.7 W

Item Standard

GENERAL SPECIFICATIONS

2 - 5

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit ---- 0.03 mm

(0.0012 in)

Cylinder:

Bore size 84.500 ~ 84.510 mm

(3.3268 ~ 3.3272 in)

84.600 mm

(3.3307 in)

Taper limit ---- 0.05 mm

(0.0016 in)

Out of round limit ---- 0.01 mm

(0.0004 in)

Camshaft:

Drive method Chain drive (Left) ----

Cam dimensions

Intake “A” 40.62 ~ 40.72 mm

(1.5992 ~ 1.6031 in)

40.52 mm

(1.5953 in)

“B” 32.18 ~ 32.28 mm

(1.2669 ~ 1.2709 in)

32.08 mm

(1.2630 in)

“C” 8.61 ~ 8.73 mm

(0.3390 ~ 0.3437 in)

----

Exhaust “A” 40.62 ~ 40.72 mm

(1.5992 ~ 1.6031 in)

40.52 mm

(1.5953 in)

“B” 32.18 ~ 32.28 mm

(1.2669 ~ 1.2709 in)

32.08 mm

(1.2630 in)

“C” 8.61 ~ 8.73 mm

(0.3390 ~ 0.3437 in)

----

Camshaft runout limit ---- 0.03 mm

(0.0012 in)

MAINTENANCE SPECIFICATIONS

2 - 6

SPEC

Cam chain:

Cam chain type/No. of links 92RH2015/116 ----

Cam chain adjustment method Automatic ----

Rocker arm/rocker arm shaft:

Shaft outside diameter 11.981 ~ 11.991 mm

(0.4717 ~ 0.4721 in)

11.951 mm

(0.4705 in)

Arm-to-shaft clearance 0.009 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

0.08 mm

(0.0031 in)

Valve, valve seat, valve guide:

Valve clearance (cold) IN 0.06 ~ 0.10 mm

(0.0024 ~ 0.0039 in)

----

EX 0.16 ~ 0.20 mm

(0.0063 ~ 0.0079 in)

----

Valve dimensions

“A” head diameter IN 39.9 ~ 40.1 mm

(1.5708 ~ 1.5787 in)

----

EX 33.9 ~ 34.1 mm

(1.3346 ~ 1.3425 in)

----

“B” face width IN 2.26 mm (0.0890 in) ----

EX 2.26 mm (0.0890 in) ----

“C” seat width IN 1.2 ~ 1.4 mm

(0.0472 ~ 0.0551 in)

1.6 mm

(0.0630 in)

EX 1.2 ~ 1.4 mm

(0.0472 ~ 0.0551 in)

1.6 mm

(0.0630 in)

“D” margin thickness IN 1.0 ~ 1.4 mm

(0.0394 ~ 0.0551 in)

----

EX 0.8 ~ 1.2 mm

(0.0314 ~ 0.0472 in)

----

Stem outside diameter IN 6.975 ~ 6.990 mm

(0.2746 ~ 0.2752 in)

6.950 mm

(0.2736 in)

EX 6.955 ~ 6.970 mm

(0.2738 ~ 0.2744 in)

6.915 mm

(0.2722 in)

Guide inside diameter IN 7.000 ~ 7.012 mm

(0.2756 ~ 0.2761 in)

7.030 mm

(0.2768 in)

EX 7.000 ~ 7.012 mm

(0.2756 ~ 0.2761 in)

7.030 mm

(0.2768 in)

Stem-to-guide clearance IN 0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

0.08 mm

(0.0031 in)

EX 0.030 ~ 0.057 mm

(0.0012 ~ 0.0022 in)

0.10 mm

(0.0039 in)

Item Standard Limit

Head Diameter

Face Width

Seat Width

Margin Thickness

MAINTENANCE SPECIFICATIONS

2 - 7

SPEC

Stem runout limit ---- 0.01 mm

(0.0004 in)

Valve seat width IN 1.2 ~ 1.4 mm

(0.0472 ~ 0.0551 in)

----

EX 1.2 ~ 1.4 mm

(0.0472 ~ 0.0551 in)

----

Valve spring:

Inner spring

Free length IN 39.9 mm (1.57 in) 37.9 mm

(1.49 in)

EX 39.9 mm (1.57 in) 37.9 mm

(1.49 in)

Set length (valve closed) IN 33.6 mm (1.32 in) ----

EX 33.6 mm (1.32 in) ----

Compressed pressure

(installed) IN 104.9 ~ 120.6 N (10.70 ~

12.30 kg, 23.58 ~ 27.11 lb)

----

EX 104.9 ~ 120.6 N (10.70 ~

12.30 kg, 23.58 ~ 27.11 lb)

----

Tilt limit IN 2.5˚/1.6 mm

(2.5˚/0.06 in)

EX 2.5˚/1.6 mm

(2.5˚/0.06 in)

Direction of winding

(top view) IN Counterclockwise ----

EX Counterclockwise ----

Outer spring

Free length IN 43.27 mm (1.70 in) 41.27 mm

(1.62 in)

EX 43.27 mm (1.70 in) 41.27 mm

(1.62 in)

Set length (valve closed) IN 36.6 mm (1.44 in) ----

EX 36.6 mm (1.44 in) ----

Item Standard Limit

MAINTENANCE SPECIFICATIONS

2 - 8

SPEC

Compressed pressure

(installed) IN 235.4 ~ 251.1 N (24.00 ~

25.60 kg, 52.92 ~ 56.45 lb)

----

EX 235.4 ~ 251.1 N (24.00 ~

25.60 kg, 52.92 ~ 56.45 lb)

----

Tilt limit IN 2.5˚/1.6 mm

(2.5˚/0.06 in)

EX 2.5˚/1.6 mm

(2.5˚/0.06 in)

Direction of winding

(top view) IN Clockwise ----

EX Clockwise ----

Piston:

Piston to cylinder clearance 0.040 ~ 0.065 mm

(0.0016 ~ 0.0026 in)

0.15 mm

(0.0059 in)

Piston size “D” 84.445 ~ 84.460 mm

(3.3246 ~ 3.3252 in)

----

Measuring point “H” 5 mm (0.20 in) ----

Piston off-set 0.5 mm (0.0200 in) ----

Piston pin bore inside diameter 20.004 ~ 20.015 mm

(0.7876 ~ 0.7880 in)

20.045 mm

(0.7892 in)

Piston pin outside diameter 19.993 ~ 20.000 mm

(0.7871 ~ 0.7874 in)

19.973 mm

(0.7863 in)

Piston rings:

Top ring

Type Barrel ----

Dimensions (B

T) 1.2

3.1 mm

(0.0472

0.1220 in)

----

End gap (installed) 0.2 ~ 0.4 mm

(0.0079 ~ 0.0157 in)

0.65 mm

(0.0256 in)

Side clearance (installed) 0.03 ~ 0.08 mm

(0.0012 ~ 0.0031 in)

0.13 mm

(0.0051 in)

Item Standard Limit

MAINTENANCE SPECIFICATIONS

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