Yamaha YFM660R User Manual

YFM660R(N)20015LP2-AE1

SERVICE MANUAL

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	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.
	CAUTION:	A CAUTION indicates special precautions that must be taken to avoid dam-
		age to the machine.
NOTE:		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.

1		2
GEN		SPEC
INFO
3		4
CHK		CHAS
ADJ
5		6
ENG		COOL
7		8
CARB		ELEC –		+
9		0
TRBL
SHTG
A		B
C		D
			T
			.
			R
			.
E	F	G
H	I	J
E		G	M
K	L	M	N
B	LS	M		S
O		P
LT			New

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter.

1 General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Carburetion

8Electrical

9Troubleshooting

Illustrated symbols 0 to G are used to identify the specifications appearing in the text.

0 Can be serviced with engine mounted A Filling fluid

BLubricant

CSpecial tool

DTorque

EWear limit, clearance

FEngine speed

GΩ, V, A

Illustrated symbols H to N in the exploded diagrams indicate the types of lubricants and lubrication points.

H Apply engine oil I Apply gear oil

J Apply molybdenum disulfide oil K Apply wheel bearing grease

L Apply lightweight lithium soap base grease M Apply molybdenum disulfide grease

N Apply silicon 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.

OApply the locking agent (LOCTITEâ)

PReplace

TABLE OF CONTENTS

GENERAL INFORMATION
	GEN								1
	INFO
SPECIFICATIONS
	SPEC								2
PERIODIC CHECKS AND
ADJUSTMENTS	CHK								3
	ADJ
CHASSIS
	CHAS								4
ENGINE
	ENG								5
COOLING SYSTEM
	COOL								6
CARBURETION
	CARB								7
			–					+
ELECTRICAL
	ELEC								8

TROUBLESHOOTING
	TRBL	9
	SHTG

INFOGEN 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

GEN

MACHINE IDENTIFICATION INFO

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.

1 - 1

IMPORTANT INFORMATION

EB101000

GEN INFO

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.

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

GEN INFO

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.

1 Oil seal

CAUTION:

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

1 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 sharpedged corner 2 is positioned opposite the thrust 3 it receives. See sectional view.

4 Shaft

1 - 3

CHECKING OF CONNECTIONS

EB801000

GEN INFO

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.

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

SPECIAL TOOLS

EB102001

SPECIAL TOOLS

GEN INFO

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	Slide hammer bolt (M6)/weight/set
90890-01083
Weight
90890-01084
Set	These tools are used to remove the rocker
YU-01083-A
	arm shaft.
90890-01135	Crankcase separating tool
YU-01135-A
	This tool is used to separate the crank-
	case.
	Crankshaft installer pot
Pot	Crankshaft installer bolt
90890-01274
Bolt
90890-01275	These tools are used to install the crank-
	shaft.
YU-90050	Crankshaft installer set
	These tools are used to install the crank-
	shaft.
Adapter	Adapter
	Spacer (crankshaft installer)
90890-04059
YM-90069
Spacer
90890-04081	These tools are used to install the crank-
YM-91044
	shaft.
90890-01016	Spacer
	This tool is used to install the crankshaft.

1 - 5

	SPECIAL TOOLS					GEN
					INFO
Tool No.	Tool name/How to use	Illustration
90890-01304	Piston pin puller
YU-01304
	This tool is used to remove the piston pin.
90890-01311	Tappet adjusting tool (3 mm)
YM-08035
	This tool is necessary for adjusting the
	valve clearance.
90890-01312	Fuel level gauge
YM-01312-A
	This gauge is used to measure the fuel
	level in the float chamber.
90890-01325	Radiator cap tester
YU-24460-01
	This tool is used to check the cooling sys-
	tem.
90890-01352	Adapter
YU-33984
	This tool is used to check the cooling sys-
	tem.
90890-01327	Damper rod holder (30 mm)
YM-01327
	This tool is needed to loosen and tighten
	the steering stem bearing retainer.
90890-01362	Flywheel puller
YU-33270
	These tools are needed to remove the
	rotor.
90890-01419	Axle nut wrench (50 mm)
YM-37132
	This tool is needed to loosen or tighten the
	rear axle nut.

1 - 6

	SPECIAL TOOLS					GEN
						INFO
Tool No.	Tool name/How to use		Illustration
90890-01469	Oil filter wrench
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.
90890-01701	Sheave holder
YS-01880	This tool is needed to hold the AC mag-
	neto rotor when removing or installing the
	AC magneto rotor bolts.
Set	Compression gauge set
	Adapter
90890-03081
YU-33223
Adapter
90890-04082	These tools are needed to measure
YU-33223-3
	engine compression.
90890-03112	Pocket tester
YU-03112
	This instrument is needed for checking the
	electrical system.
90890-03141	Timing light
YM-33277-A
	This tool is necessary for checking ignition
	timing.
	Carburetor angle driver
90890-03158
	This tool is used to turn the pilot screw
	when adjusting the engine idling speed.

1 - 7

	SPECIAL TOOLS				GEN
					INFO
Tool No.	Tool name/How to use	Illustration
Compressor	Valve spring compressor
	Valve spring compressor attachment
90890-04019
YM-04019
Attachment	This tool is needed to remove and install
90890-01243
	the valve assemblies.
Middle driven shaft	Middle driven shaft bearing driver
bearing driver	Mechanical seal installer
90890-04058
YM-04058-1
Mechanical seal
installer	These tools are used to install the water
90890-04078
	pump seal.
YM-33221
90890-04064	Valve guide remover (ø 6)
YM-4064-A
	This tool is needed to remove and install
	the valve guide.
90890-04065	Valve guide installer (ø 6)
YM-04065-A
	This tool is needed to install the valve
	guide.
90890-04066	Valve guide reamer (ø 6)
YM-04066
	This tool is needed to rebore the new
	valve guide.
90890-04086	Clutch holding tool
YM-91042	This tool is needed to hold the clutch car-
	rier when removing or installing the carrier
	nut.
90890-06754	Ignition checker
	This instrument is necessary for checking
	the ignition system components.
YM-34487	Dynamic spark tester
	This instrument is necessary for checking
	the ignition system components.

1 - 8

		SPECIAL TOOLS			GEN
					INFO
Tool No.	Tool name/How to use		Illustration
	Yamaha bond No. 1215
Bond	Sealant (Quick Gasket®)
90890-85505
Sealant
ACC-11001-05-01	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			SPEC
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 cm3
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/cm2, 181 psi)
Starting system	Electric starter
Lubrication system:	Dry sump
Oil type or grade:
Engine oil
For CDN

0°	10°	30°	50°	70°	90°	110°	130°F	API service SE, SF, SG type or higher
		YAMALUBE 4 (20W40) or SAE 20W40
	YAMALUBE 4 (10W30) or SAE 10W30
SAE 5W30
-20°	-10°	0°	10°	20°	30°	40°	50°C

For Europe

	Temp.
-20° -10°	0°	10°	20°	30°	40°	50°C
5W/30
		10W/30
		10W/40
			15W/40
			20W/40
			20W/50

2 - 1

	GENERAL SPECIFICATIONS			SPEC
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)

2 - 2

GENERAL SPECIFICATIONS SPEC

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/cm2, 4.0 psi)
	rear	27.5 kPa (0.275 kg/cm2, 4.0 psi)
*Load in total weight of cargo, rider and acces-
sories
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:		12 V 30 W/30 W × 2
Headlight
Tail/brake light		12 V 5 W/21 W × 1
Indicator and warning lights		12 V 1.7 W × 1
Neutral
Reverse		12 V 1.7 W × 1
Coolant temperature		12 V 1.7 W × 1

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	100.1 mm
Measuring point *	(3.9372 ~ 3.9388 in)	(3.94 in)
	50 mm (2.0 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	35.59 mm
							(1.4051 ~ 1.4091 in)	(1.4012 in)
			“B”				30.15 ~ 30.25 mm	30.05 mm
							(1.1870 ~ 1.1909 in)	(1.1831 in)
			“C”				5.74 mm (0.2260 in)	----
Exhaust			“A”				36.50 ~ 36.60 mm	36.40 mm
							(1.437 ~ 1.441 in)	(1.4331 in)
			“B”				30.15 ~ 30.25 mm	30.05 mm
							(1.187 ~ 1.191 in)	(1.1831 in)
			“C”				6.55 mm (0.2579 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
					B		C
		A					Seat Width			D
					Face Width			Margin Thickness
	Head Diameter
“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			1.6 mm
							(0.0354 ~ 0.0433 in)			(0.0630 in)
					EX		0.9 ~ 1.1 mm			1.6 mm
							(0.0354 ~ 0.0433 in)			(0.0630 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			5.945 mm
							(0.2352 ~ 0.2358 in)			(0.2341 in)
					EX		5.960 ~ 5.975 mm			5.930 mm
							(0.2346 ~ 0.2352 in)			(0.2335 in)
Guide inside diameter					IN		6.000 ~ 6.012 mm			6.040 mm
							(0.2362 ~ 0.2367 in)			(0.2378 in)
					EX		6.000 ~ 6.012 mm			6.040 mm
							(0.2362 ~ 0.2367 in)			(0.2378 in)

2 - 5

MAINTENANCE SPECIFICATIONS

SPEC

Item

Standard

Limit

Stem-to-guide clearance

IN

0.010 ~ 0.037 mm

0.08 mm

(0.0004 ~ 0.0015 in)

(0.0031 in)

EX

0.025 ~ 0.052 mm

0.10 mm

(0.0010 ~ 0.0020 in)

(0.0039 in)

Stem runout limit

----

0.01 mm

(0.0004 in)

Valve seat width	IN	0.9 ~ 1.1 mm	1.6 mm
		(0.0354 ~ 0.0433 in)	(0.0630 in)
	EX	0.9 ~ 1.1 mm	1.6 mm
		(0.0354 ~ 0.0433 in)	(0.0630 in)
Valve spring:
Free length	IN	35.95 mm (1.42 in)	34.15 mm
			(1.34 in)
	EX	37.75 mm (1.49 in)	35.86 mm
			(1.41 in)
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,	----
Tilt limit*		37.09 ~ 42.94 lb)
	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	----

2 - 6

	MAINTENANCE SPECIFICATIONS			SPEC
	Item	Standard			Limit
Piston:
Piston to cylinder clearance		0.05 ~ 0.07 mm		0.15 mm
		(0.0020 ~ 0.0028 in)		(0.0059 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

22.045 mm

(0.8663 ~ 0.8667 in)

(0.8679 in)

Piston pin outside diameter

21.991 ~ 22.000 mm

21.971 mm

(0.8658 ~ 0.8661 in)

(0.8650 in)

Piston rings:

Top ring

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

0.70 mm

(0.0118 ~ 0.0177 in)

(0.0276 in)

Side clearance (installed)

0.04 ~ 0.08 mm

0.13 mm

(0.0016 ~ 0.0031 in)

(0.0051 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

0.80 mm

(0.0118 ~ 0.0177 in)

(0.0315 in)

Side clearance

0.03 ~ 0.07 mm

0.13 mm

(0.0012 ~ 0.0028 in)

(0.0051 in)

Oil ring

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