YAMAHA YFM400FWA(M) 2000 SERVICE MANUAL

2000

YFM400FWA

(

)

5GH3-AE1

SERVICE MANUAL

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 maintenance 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!

WARNING

CAUTION:

NOTE:

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.

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2 : 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 3 : 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 4 is provided for removal and disassembly jobs.

2. Numbers 5 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 6 . The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7 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 8 are given in addition to the exploded diagram and the job instruction chart.

GEN

INFO

SPEC

INSP

ADJ

COOL

DRIV

–+

ELEC

ENG

CARB

CHAS

TRBL

SHTG

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 0 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 A to H are used to identify the specifications appearing in the text.

IJK

LMN

O P

New

Can be serviced with engine mounted Filling fluid Lubricant Special tool Torque Wear limit, clearance Engine speed

, V, A

Ω

Illustrated symbols I to N 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

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND ADJUSTMENTS

ENGINE

COOLING SYSTEM

GEN

INFO

SPEC

INSP

ADJ

ENG

COOL

1 2 3 4 5

CARBURETION

DRIVE TRAIN

CHASSIS

ELECTRICAL

TROUBLESHOOTING

CARB

DRIV

CHAS

–+

ELEC

TRBL

SHTG

6 7 8 9

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

GEN

MACHINE IDENTIFICATION

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the left side of the frame.

MODEL LABEL

The model label 1 is affixed to the frame. This information will be needed to order spare parts.

INFO

1 - 1

GEN

FEATURES

LIQUID COOLING ENGINE

Compact liquid cooled 45˚ inclined engine. A liquid cooling system has been incorporated for stable power and engine endurance.

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.

INFO

When the drive select lever is at the “L”, “H”, “N”, or “R” positions, the stopper lever end 1 is moved away from the stopper gear 2 by the return spring 3 . When the drive select lever is in the “P” position, the lever cam 4 at the side of the shift cam 5 lifts the stopper lever end 6 and the stopper lever end locks the drive axle 7 .

When the stopper lever end 1 is not synchronized, a torsion spring 8 retains the rotation force of the shift cam 5 until it is synchronized.

1 - 2

IMPORTANT INFORMATION

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 assembly and allow for the correct installation of all parts.

5.Keep all parts away from any source of fire.

GEN

INFO

EB101010

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.

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.

1 - 3

IMPORTANT INFORMATION

EB101030

LOCK WASHERS/PLATES AND COTTER PINS

1.Replace all lock washers/plates 1 and cotter 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 visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate.

Oil seal

GEN

INFO

CAUTION:

Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.

Bearing

EB101050

CIRCLIPS

1.Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1 , make sure that the sharp-edged corner 2 is positioned opposite the thrust 3 it receives. See sectional view.

Shaft

1 - 4

CHECKING OF CONNECTIONS

EB801000

CHECKING OF CONNECTIONS

Check the connectors for stains, rust, moisture, etc.

1.Disconnect:

●

Connector

2.Check: Connector

●

Moisture blower. Stains/rust terminals several times.

3.Check: Connector leads

●

Looseness nect the terminals.

→

Dry each terminal with an air

→

Connect and disconnect the

→

Bend up the pin 1 and con-

GEN

INFO

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 revitalizer available at most part stores. Check the connector with a pocket tester

●

as shown.

1 - 5

GEN

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

INFO

Bolt

90890-01083

Weight

90890-01084

Set

YU-01083-A

90890-01135

YU-01135-A

90890-01225 YM-01225-A

90890-04017

YM-04017

Slide hammer bolt (M6)/weight/set

These tools are used to remove the rocker arm shaft.

Crankcase separating tool

This tool is used to separate the crankcase.

Valve guide remover (7.0 mm)

This tool is needed to remove and install the valve guide.

Valve guide installer (7.0 mm)

This tool is needed to install the valve guide.

Valve guide reamer (7.0 mm)

90890-01227

YM-01227

90890-01231

YM-01231

90890-01235

YU-01235

This tool is needed to rebore the new valve guide.

Gear lash measurement tool

This tool is used to measure the gear lash.

Rotor holding tool

This tool is needed to hold the starter puller when removing/installing the starter puller bolt or camshaft sprocket bolts.

1 - 6

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Buffer boss installer set

Kit

90890-04088

Bolt

90890-01275

YU-90050

Crankshaft installer bolt

These tools are used to install the crankshaft.

Crankshaft installer set

These tools are used to install the crankshaft.

INFO

Adapter

YM-33279

Spacer 90890-04060 YM-90070-A

90890-01304

YU-01304

90890-01311

YU-08035

90890-01312 YM-01312-A

Adapter (#11) Spacer (crankshaft installer)

These tools are used to install the crankshaft.

Piston pin puller

This tool is used to remove the piston pin.

Tappet adjusting tool (3 mm)

This tool is necessary for adjusting the valve clearance.

Fuel level gauge

This gauge is used to measure the fuel level in the float chamber.

Radiator cap tester

90890-01325

YU-24460-01

90890-01352

YU-33984

90890-01348

This tool is used to check the cooling system.

Adapter

This tool is used to check the cooling system.

Locknut wrench

This tool is needed when removing or installing the secondary sheave spring.

1 - 7

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Sheave spring compressor

INFO

90890-04134

YM-04134

90890-04135

YM-04135

90890-01404

YM-01404

90890-01327

YM-01327

90890-01426

YU-38411

This tool is needed when removing or installing the secondary sheave spring.

Sheave fixed block

This tool is needed when removing or installing the secondary sheave spring.

Flywheel puller

These tools are needed to remove the rotor.

Damper rod holder (30 mm)

This tool is needed to loosen and tighten the steering stem bearing retainer.

Oil filter wrench

This tool is needed to loosen or tighten the oil filter cartridge.

90890-01430

YM-38404

90890-01467

YM-01467

90890-01475

YM-01475

90890-01701

YU-01880

Set

90890-03081

YU-33223

Adapter

90890-04082

YU-33223-3

Ring nut wrench

This tool is needed to removing and installing the middle driven shaft bearing retainer.

Gear lash measurement tool

This tool is used to measure the gear lash.

Sheave holder

This tool is needed to hold the primary sheave when removing or installing the sheave bolts.

Compression gauge set Adapter

These tools are needed to measure engine compression.

1 - 8

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Pocket tester

90890-03112

YU-03112

This instrument is needed for checking the electrical system.

Engine tachometer

90890-03113

This tool is needed for observing engine rpm.

Inductive tachometer

YU-8036-A

This tool is needed for observing engine rpm.

Timing light

INFO

90890-03141 YM-33277-A

90890-04019

YM-04019

Middle driven shaft

bearing driver

90890-04058

YM-04058-1

Mechanical seal

installer

90890-04078

YM-33221

90890-04050

YM-04050

90890-04062

YM-04062

This tool is necessary for checking ignition timing.

Valve spring compressor

This tool is needed to remove and install the valve assemblies.

Middle driven shaft bearing driver Mechanical seal installer

These tools are used to install the water pump seal.

Bearing retainer wrench

This tool is needed when removing or installing the final drive shaft bearing retainer.

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.

1 - 9

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Bearing retainer wrench

INFO

90890-04128

YM-04128

90890-04129

YM-04129

90890-06754

YM-34487

Bond

90890-85505

Sealant

ACC-11001-05-01

This tool is needed when removing or installing the middle driven pinion gear bearing retainer.

Pinion gear fix clamp

This tool is used to hold the shift cam.

Ignition checker

This instrument is necessary for checking the ignition system components.

Dynamic spark tester

This instrument is necessary for checking the ignition system components.

Yamaha bond No. 1215 Sealant (Quick Gasket®)

This sealant (bond) is used on crankcase mating surfaces, etc.

1 - 10

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

GENERAL SPECIFICATIONS

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

SPEC

0° 10° 30° 50° 70° 90° 110°

YAMALUBE 4 (20W40) or SAE 20W40

YAMALUBE 4 (10W30) or SAE 10W30

SAE 5W30

-20° -10° 0° 10° 20° 30° 40°

130°F

API service SE, SF, SG type or higher

50°C

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)

2 - 1

GENERAL SPECIFICATIONS

Item Standard

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

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)

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

Regular unleaded gasoline (For CDN, GB, F, CH) Unleaded fuel only (For Oceania)

D8EA/NGK (For Oceania) X24ES-U/DENSO (For Oceania)

SPEC

2 - 2

GENERAL SPECIFICATIONS

Item Standard

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)

SPEC

2 - 3

GENERAL SPECIFICATIONS

Item Standard

Tire pressure (cold tire):

Maximum load* 210 kg (463 lb)

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

rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm *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 × 2

Tail light 12 V 7.5 W × 1

Meter light 14 V 3.4 W × 1

Indicator lights

Neutral 14 V 1.7 W × 1 Reverse 14 V 1.7 W × 1 Coolant temperature 14 V 1.7 W × 1 Four-wheel drive 14 V 1.7 W × 1 Park 14 V 1.7 W × 1

SPEC

, 3.2 ~ 4.0 psi)

2 - 4

MAINTENANCE SPECIFICATIONS

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)

Taper limit ---- 0.05 mm

Out of round limit ---- 0.01 mm

Camshaft:

Drive method Chain drive (Left) ----

Cam dimensions

84.600 mm (3.3307 in)

(0.0016 in)

(0.0004 in)

Intake “A” 40.62 ~ 40.72 mm

(1.5992 ~ 1.6031 in)

“B” 32.18 ~ 32.28 mm

(1.2669 ~ 1.2709 in)

“C” 8.61 ~ 8.73 mm

(0.3390 ~ 0.3437 in)

Exhaust “A” 40.62 ~ 40.72 mm

(1.5992 ~ 1.6031 in)

“B” 32.18 ~ 32.28 mm

(1.2669 ~ 1.2709 in)

“C” 8.61 ~ 8.73 mm

(0.3390 ~ 0.3437 in)

Camshaft runout limit ---- 0.03 mm

40.52 mm (1.5953 in)

32.08 mm (1.2630 in)

----

40.52 mm (1.5953 in)

32.08 mm (1.2630 in)

----

(0.0012 in)

2 - 5

MAINTENANCE SPECIFICATIONS

SPEC

Item Standard Limit

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)

Arm-to-shaft clearance 0.009 ~ 0.037 mm

(0.0004 ~ 0.0015 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

Head Diameter

Face Width

Seat Width

Margin Thickness

11.951 mm (0.4705 in)

0.08 mm (0.0031 in)

----

“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)

EX 1.2 ~ 1.4 mm

(0.0472 ~ 0.0551 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)

EX 6.955 ~ 6.970 mm

(0.2738 ~ 0.2744 in)

Guide inside diameter IN 7.000 ~ 7.012 mm

(0.2756 ~ 0.2761 in)

EX 7.000 ~ 7.012 mm

(0.2756 ~ 0.2761 in)

Stem-to-guide clearance IN 0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

EX 0.030 ~ 0.057 mm

(0.0012 ~ 0.0022 in)

----

1.6 mm (0.0630 in)

----

6.950 mm (0.2736 in)

6.915 mm (0.2722 in)

7.030 mm (0.2768 in)

0.08 mm (0.0031 in)

0.10 mm (0.0039 in)

2 - 6

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Stem runout limit ---- 0.01 mm

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

EX 39.9 mm (1.57 in) 37.9 mm

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

EX 2.5˚/1.6 mm

SPEC

(0.0004 in)

----

(1.49 in)

----

(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) ----

2 - 7

MAINTENANCE SPECIFICATIONS

Item Standard Limit

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

Direction of winding (top view) IN Clockwise ----

Piston:

Piston to cylinder clearance 0.040 ~ 0.065 mm

Piston size “D” 84.445 ~ 84.460 mm

EX 2.5˚/1.6 mm

EX Clockwise ----

(0.0016 ~ 0.0026 in)

(3.3246 ~ 3.3252 in)

SPEC

----

(2.5˚/0.06 in)

0.15 mm (0.0059 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)

Piston pin outside diameter 19.993 ~ 20.000 mm

(0.7871 ~ 0.7874 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)

Side clearance (installed) 0.03 ~ 0.08 mm

(0.0012 ~ 0.0031 in)

20.045 mm (0.7892 in)

19.973 mm (0.7863 in)

----

0.65 mm (0.0256 in)

0.13 mm (0.0051 in)

2 - 8

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