Yamaha YFM660R User Manual
2001
YFM660R
(
N
)
5LP2-AE1
SERVICEMANUAL
YFM660R(N) 2001
SERVICE MANUAL
2000 by Yamaha Motor Co., Ltd.
First Edition, July 2000
All rights reserved. Any reproduction or
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.
NOTE:
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 accompa-
nied 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.
12
GEN
INFO
34
SPEC
CHK
CHAS
ADJ
56
ENG
78
COOL
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are printed on the
top right of each page and indicate the subject
of each chapter.
General information
1
Specifications
2
Periodic checks and adjustments
3
Chassis
4
Engine
5
Cooling system
6
Carburetion
7
Electrical
8
Troubleshooting
9
CARB
90
ELEC
–+
TRBL
SHTG
AB
CD
T
.
R
.
EFG
HIJ
Illustrated symbols 0 to G are used to identify
the specifications appearing in the text.
Can be serviced with engine mounted
0
Filling fluid
A
Lubricant
B
Special tool
C
Torque
D
Wear limit, clearance
E
Engine speed
F
, V, A
Ω
G
Illustrated symbols H to N in the exploded
diagrams indicate the types of lubricants and
lubrication points.
LS
G
M
M
S
New
E
K
OP
LMN
B
LT
Apply engine oil
H
Apply gear oil
I
Apply molybdenum disulfide oil
J
Apply wheel bearing grease
K
Apply lightweight lithium soap base grease
L
Apply molybdenum disulfide grease
M
Apply silicon grease
N
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.
Apply the locking agent (LOCTITE
O
Replace
P
)
TABLE OF CONTENTS
–+
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
1
2
3
4
5
COOLING SYSTEM
CARBURETION
ELECTRICAL
TROUBLESHOOTING
COOL
CARB
ELEC
TRBL
SHTG
6
7
8
9
GEN
INFO
1
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ..........................................................................1-1
VEHICLE IDENTIFICATION NUMBER ....................................................1-1
MODEL LABEL .........................................................................................1-1
IMPORTANT INFORMATION ........................................................................1-2
PREPARATION FOR REMOVAL PROCEDURES ..................................1-2
REPLACEMENT PARTS ..........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ...................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS ....................................1-3
BEARINGS AND OIL SEALS ...................................................................1-3
CIRCLIPS .................................................................................................1-3
CHECKING OF CONNECTIONS ...................................................................1-4
SPECIAL TOOLS ...........................................................................................1-5
GEN
INFO
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 air filter
case cover. This information will be needed to
order spare parts.
GEN
INFO
1 - 1
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 - 2
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
1
GEN
INFO
CAUTION:
Do not use compressed air to spin the
bearings dry. This will damage the bearing
surfaces.
Bearing
1
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 sharpedged corner 2 is positioned opposite the
thrust 3 it receives. See sectional view.
Shaft
4
1 - 3
CHECKING OF CONNECTIONS
EB801000
CHECKING OF CONNECTIONS
Check the connectors for stains, rust, moisture, 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 1 and connect the terminals.
GEN
INFO
4.Connect:
●
Connector terminals
NOTE:
The two terminals “click” together.
5.Check:
●
Continuity (using a pocket tester)
NOTE:
●
If there is no continuity, clean the terminals.
●
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 - 4
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
Pot
90890-01274
Bolt
90890-01275
YU-90050
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.
Crankshaft installer pot
Crankshaft installer bolt
These tools are used to install the crankshaft.
Crankshaft installer set
These tools are used to install the crankshaft.
Adapter
90890-04059
YM-90069
Spacer
90890-04081
YM-91044
90890-01016
Adapter
Spacer (crankshaft installer)
These tools are used to install the crankshaft.
Spacer
This tool is used to install the crankshaft.
1 - 5
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Piston pin puller
90890-01304
YU-01304
This tool is used to remove the piston pin.
Tappet adjusting tool (3 mm)
90890-01311
YM-08035
This tool is necessary for adjusting the
valve clearance.
Fuel level gauge
90890-01312
YM-01312-A
This gauge is used to measure the fuel
level in the float chamber.
INFO
90890-01325
YU-24460-01
90890-01352
YU-33984
90890-01327
YM-01327
90890-01362
YU-33270
Radiator cap tester
This tool is used to check the cooling system.
Adapter
This tool is used to check the cooling system.
Damper rod holder (30 mm)
This tool is needed to loosen and tighten
the steering stem bearing retainer.
Flywheel puller
These tools are needed to remove the
rotor.
90890-01419
YM-37132
Axle nut wrench (50 mm)
This tool is needed to loosen or tighten the
rear axle nut.
1 - 6
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Oil filter wrench
90890-01469
YM-01469
This tool is needed to loosen or tighten
the oil filter cartridge.
Ball joint remover/installer set
90890-01474
YM-01474
These tools are used to removing or
installing the ball joint.
Ball joint remover/installer attachment set
90890-01480
YM-01480
These tools are used to removing or
installing the ball joint.
INFO
90890-01701
YS-01880
Set
90890-03081
YU-33223
Adapter
90890-04082
YU-33223-3
90890-03112
YU-03112
90890-03141
YM-33277-A
Sheave holder
This tool is needed to hold the AC magneto rotor when removing or installing the
AC magneto rotor bolts.
Compression gauge set
Adapter
These tools are needed to measure
engine compression.
Pocket tester
This instrument is needed for checking the
electrical system.
Timing light
This tool is necessary for checking ignition
timing.
90890-03158
Carburetor angle driver
This tool is used to turn the pilot screw
when adjusting the engine idling speed.
1 - 7
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
INFO
Compressor
90890-04019
YM-04019
Attachment
90890-01243
Middle driven shaft
bearing driver
90890-04058
YM-04058-1
Mechanical seal
installer
90890-04078
YM-33221
90890-04064
YM-4064-A
90890-04065
YM-04065-A
Valve spring compressor
Valve spring compressor attachment
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.
Valve guide remover (ø 6)
This tool is needed to remove and install
the valve guide.
Valve guide installer (ø 6)
This tool is needed to install the valve
guide.
90890-04066
YM-04066
90890-04086
YM-91042
90890-06754
YM-34487
Valve guide reamer (ø 6)
This tool is needed to rebore the new
valve guide.
Clutch holding tool
This tool is needed to hold the clutch carrier when removing or installing the carrier
nut.
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.
1 - 8
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
INFO
Bond
90890-85505
Sealant
ACC-11001-05-01
Yamaha bond No. 1215
Sealant (Quick Gasket
This sealant (bond) is used on crankcase
mating surfaces, etc.
®
)
1 - 9
GEN
INFO
1 - 10
SPEC
2
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................2-1
MAINTENANCE SPECIFICATIONS ..............................................................2-4
ENGINE ....................................................................................................2-4
CHASSIS ................................................................................................2-14
ELECTRICAL .........................................................................................2-18
HOW TO USE THE CONVERSION TABLE .................................................2-20
GENERAL TORQUE SPECIFICATIONS .....................................................2-20
LUBRICATION POINTS AND LUBRICANT TYPES ...................................2-21
ENGINE ..................................................................................................2-21
COOLANT FLOW DIAGRAMS ....................................................................2-22
OIL FLOW DIAGRAMS ................................................................................2-23
CABLE ROUTING ........................................................................................2-27
SPEC
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: 5LP2 : (For CDN)
5LP4 : (For Europe)
Dimensions:
Overall length 1,830 mm (72.0 in)
Overall width 1,100 mm (43.3 in)
Overall height 1,150 mm (45.3 in)
Seat height 860 mm (33.9 in)
Wheelbase 1,245 mm (49.0 in)
Minimum ground clearance 265 mm (10.4 in)
Minimum turning radius 3,300 mm (129.9 in)
Basic weight:
With oil and full fuel tank 193 kg (426 lb)
Engine:
Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 660 cm
Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in)
Compression ratio 9.2 : 1
Standard compression pressure (at sea level) 1,250 kPa (12.5 kg/cm
Starting system Electric starter
Lubrication system: Dry sump
Oil type or grade:
Engine oil
For CDN
3
2
, 181 psi)
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 °
For Europe
Temp.
-20 ° -10 ° 0 ° 10 ° 20 ° 30 ° 40 ° 50 ° C
5W/30
10W/30
10W/40
15W/40
20W/40
20W/50
130°F
50 °C
API service SE, SF, SG type or higher
2 - 1
GENERAL SPECIFICATIONS
Item Standard
Oil capacity:
Engine oil
Periodic oil change 1.9 L (1.67 lmp qt, 2.01 US qt)
With oil filter replacement 1.95 L (1.72 lmp qt, 2.06 US qt)
Total amount 2.3 L (2.02 lmp qt, 2.43 US qt)
Radiator capacity (including all routes) 1.3 L (1.14 lmp qt, 1.37 US qt)
Air filter: Wet type element
Fuel:
Type Regular unleaded fuel
Fuel tank capacity 12 L (2.64 lmp gal, 3.17 US gal)
Fuel reserve amount 2.6 L (0.57 lmp gal, 0.69 US gal)
Carburetor:
Type/quantity BSR33/2
Manufacturer MIKUNI
Spark plug:
Type/manufacturer DPR8EA-9/NGK
Spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in)
Clutch type: Wet, multiple disc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 71/34 (2.088)
Secondary reduction system Chain drive
Secondary reduction ratio 40/13 (3.076)
Transmission type Constant mesh, 5-speed/forward.
1-speed/reverse
Operation Left foot operation
Gear ratio
1st gear 34/14 (2.428)
2nd gear 29/19 (1.526)
3rd gear 26/21 (1.238)
4th gear 22/21 (1.047)
5th gear 19/21 (0.904)
Reverse gear 28/23 × 23 × 16 (1.750)
Chassis:
Frame type Steel tube frame
Caster angle 8°
Camber angle –1°
Kingpin angle 14.5°
Kingpin offset 5 mm (0.20 in)
Trail 47 mm (1.85 in)
Tread (STD) front 925 mm (36.42 in)
rear 840 mm (33.07 in)
Toe-in 0 ~ 10 mm (0 ~ 0.39 in)
SPEC
2 - 2
GENERAL SPECIFICATIONS
Item Standard
Tire:
Type Tubeless
Size front AT21 × 7–10
rear AT20 × 10–9
Manufacturer front DUNLOP
rear DUNLOP
Type front KT331 Radial
rear KT335 Radial
Tire pressure (cold tire):
Maximum load* 100 kg (220 lb)
Off-road riding front 27.5 kPa (0.275 kg/cm
rear 27.5 kPa (0.275 kg/cm
*Load in total weight of cargo, rider and accessories
Brake:
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Single disc brake
operation Right foot operation
Suspension:
Front suspension Double wishbone
Rear suspension Swingarm (link suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas-oil damper
Wheel travel:
Front wheel travel 230 mm (9.06 in)
Rear wheel travel 220 mm (8.66 in)
Electrical:
Ignition system DC-C.D.I.
Generator system A.C. magneto
Battery type YTX14-BS
Battery capacity 12 V 12 Ah
Headlight type: Krypton bulb
Bulb voltage/wattage × quantity:
Headlight 12 V 30 W/30 W × 2
Tail/brake light 12 V 5 W/21 W × 1
Indicator and warning lights
Neutral 12 V 1.7 W × 1
Reverse 12 V 1.7 W × 1
Coolant temperature 12 V 1.7 W × 1
SPEC
2
, 4.0 psi)
2
, 4.0 psi)
2 - 3
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.05 mm
(0.002 in)
Cylinder:
Bore size 100.005 ~ 100.045 mm
(3.9372 ~ 3.9388 in)
Measuring point
*
50 mm (2.0 in) ----
100.1 mm
(3.94 in)
Camshaft:
Drive method Chain drive (Left) ---Camshaft cap inside diameter 23.000 ~ 23.021 mm
(0.9055 ~ 0.9063 in)
Camshaft journal diameter 22.967 ~ 22.980 mm
(0.9042 ~ 0.9047 in)
Camshaft journal-to-camshaft cap clearance 0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)
Cam dimensions
C
A
B
Intake “A” 35.69 ~ 35.79 mm
(1.4051 ~ 1.4091 in)
“B” 30.15 ~ 30.25 mm
(1.1870 ~ 1.1909 in)
“C” 5.74 mm (0.2260 in) ----
Exhaust “A” 36.50 ~ 36.60 mm
(1.437 ~ 1.441 in)
“B” 30.15 ~ 30.25 mm
(1.187 ~ 1.191 in)
“C” 6.55 mm (0.2579 in) ----
----
----
----
35.59 mm
(1.4012 in)
30.05 mm
(1.1831 in)
36.40 mm
(1.4331 in)
30.05 mm
(1.1831 in)
2 - 4
MAINTENANCE SPECIFICATIONS
SPEC
Item Standard Limit
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
Timing chain:
Timing chain type/No. of links 75-RH2015/126 ---Timing chain adjustment method Automatic ----
Rocker arm/rocker arm shaft:
Shaft outside diameter 11.976 ~ 11.991 mm
----
(0.4715 ~ 0.4721 in)
Arm-to-shaft clearance 0.009 ~ 0.042 mm
----
(0.0004 ~ 0.0017 in)
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.10 ~ 0.15 mm
----
(0.0039 ~ 0.0059 in)
EX 0.15 ~ 0.20 mm
----
(0.0059 ~ 0.0079 in)
Valve dimensions
A
Head Diameter
Face Width
B
Seat Width
C
Margin Thickness
“A” head diameter IN 29.9 ~ 30.1 mm
(1.1772 ~ 1.1850 in)
EX 31.9 ~ 32.1 mm
(1.2559 ~ 1.2638 in)
“B” face width IN 2.25 mm (0.0886 in) ----
EX 2.26 mm (0.0890 in) ----
“C” seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
“D” margin thickness IN 0.85 ~ 1.15 mm
(0.0335 ~ 0.0453 in)
EX 0.85 ~ 1.15 mm
(0.0335 ~ 0.0453 in)
Stem outside diameter IN 5.975 ~ 5.990 mm
(0.2352 ~ 0.2358 in)
EX 5.960 ~ 5.975 mm
(0.2346 ~ 0.2352 in)
Guide inside diameter IN 6.000 ~ 6.012 mm
(0.2362 ~ 0.2367 in)
EX 6.000 ~ 6.012 mm
(0.2362 ~ 0.2367 in)
D
----
----
1.6 mm
(0.0630 in)
1.6 mm
(0.0630 in)
----
----
5.945 mm
(0.2341 in)
5.930 mm
(0.2335 in)
6.040 mm
(0.2378 in)
6.040 mm
(0.2378 in)
2 - 5
MAINTENANCE SPECIFICATIONS
Item Standard Limit
Stem-to-guide clearance IN 0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
EX 0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
Stem runout limit ---- 0.01 mm
SPEC
0.08 mm
(0.0031 in)
0.10 mm
(0.0039 in)
(0.0004 in)
Valve seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
Valve spring:
Free length IN 35.95 mm (1.42 in) 34.15 mm
EX 37.75 mm (1.49 in) 35.86 mm
Set length (valve closed) IN 27.2 mm (1.07 in) ----
EX 30.7 mm (1.21 in) ----
Compressed pressure
(installed) IN 149 ~ 173 N (15.19 ~ 17.64 kg,
33.50 ~ 38.89 lb)
EX 165 ~ 191 N (16.83 ~ 19.49 kg,
37.09 ~ 42.94 lb)
Tilt limit IN ---- 2.5°/1.6 mm
*
EX ---- 2. 5 ° / 1 . 6 m m
1.6 mm
(0.0630 in)
1.6 mm
(0.0630 in)
(1.34 in)
(1.41 in)
----
----
(2.5°/0.06 in)
(2.5°/0.06 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ----
2 - 6
MAINTENANCE SPECIFICATIONS
Item Standard Limit
Piston:
Piston to cylinder clearance 0.05 ~ 0.07 mm
(0.0020 ~ 0.0028 in)
Piston size “D” 99.945 ~ 99.995 mm
(3.9348 ~ 3.9368 in)
H
D
Measuring point “H” 2.5 mm (0.10 in) ---Piston off-set 1.0 mm (0.04 in) ---Piston pin bore inside diameter 22.004 ~ 22.015 mm
(0.8663 ~ 0.8667 in)
Piston pin outside diameter 21.991 ~ 22.000 mm
(0.8658 ~ 0.8661 in)
Piston rings:
Top ring
SPEC
0.15 mm
(0.0059 in)
----
22.045 mm
(0.8679 in)
21.971 mm
(0.8650 in)
B
T
Type Barrel ---Dimensions (B × T) 1.2 × 3.8 mm
(0.0472 × 0.1496 in)
End gap (installed) 0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)
Side clearance (installed) 0.04 ~ 0.08 mm
(0.0016 ~ 0.0031 in)
2nd ring
B
T
Type Taper ---Dimensions (B × T) 1.2 × 4.0 mm
(0.0472 × 0.1575 in)
End gap (installed) 0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)
Side clearance 0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in)
Oil ring
----
0.70 mm
(0.0276 in)
0.13 mm
(0.0051 in)
----
0.80 mm
(0.0315 in)
0.13 mm
(0.0051 in)
B
T
Dimensions (B × T) 2.5 × 3.4 mm
(0.0984 × 0.1339 in)
End gap (installed) 0.2 ~ 0.7 mm
(0.0079 ~ 0.0276 in)
2 - 7
----
----
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