Yamaha YFZ450 User Manual

YFZ450S
5TG2-AE1
SERVICE MANUAL
EBS00000
YFZ450S
SERVICE MANUAL
©2003 by Yamaha Motor Co., Ltd.
First Edition, April 2003
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd. is expressly prohibited.
EBS00002
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.
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
WARNING
CAUTION:
NOTE:
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 checking 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.
EBS00004
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “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.
12
GEN
SPEC
INFO
34
CHK
ENG
ADJ
56
COOL
78
CARB
EBS00006
SYMBOLS
The following symbols are not relevant to every machine. Symbols 1 to 9 indicate the subject of each chapter.
General information
1
Specifications
2
Periodic checks and adjustments
3
Engine
4
Cooling system
5
Carburetor
6
Chassis
7
Electrical
8
Troubleshooting
9
CHAS
90
ELEC
–+
TRBL SHTG
AB
CD
T
.
R
.
EFG
HIJ
LS
G
M
M
E
KLM
B
Symbols 0 to G indicate the following
Serviceable with engine mounted
0
Filling fluid
A
Lubricant
B
Special tool
C
Torque
D
Wear limit, clearance
E
Engine speed
F
Electrical data (Ω, V, A)
G
Symbols H to N in the exploded diagrams indicate the types of lubricants and lubrication points.
Apply engine oil
H
Apply gear oil
I
Apply molybdenum disulfide oil
J
Apply wheel bearing grease
K
Apply lithium-soap-based grease
L
Apply molybdenum disulfide grease
M
NO
LT
New
Symbols N to O in the exploded diagrams indicate where to apply a locking agent N and when to install a new part O.
®
Apply the locking agent (LOCTITE
N
Replace
O
)
EBS00008
+
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND ADJUSTMENTS
ENGINE
COOLING SYSTEM
GEN
INFO
SPEC
CHK
ADJ
ENG
COOL
1
2
3
4
5
CARBURETOR
CHASSIS
ELECTRICAL
TROUBLESHOOTING
CARB
CHAS
ELEC
TRBL SHTG
6
7
8
9
GEN
INFO
1
CHAPTER 1

GENERAL INFORMATION

GEN
INFO
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2
REPLACEMENT PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-3
BEARINGS AND OIL SEALS ....................................................................1-3
CIRCLIPS ..................................................................................................1-3
CHECKING THE CONNECTIONS............................................................1-4
SPECIAL TOOLS
............................................................................................1-5
...........................................................................1-1
.........................................................................1-2
GEN
INFO
1
1
MACHINE IDENTIFICATION
EBS00009
GENERAL INFORMATION
MACHINE IDENTIFICATION
EBS00010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped into the left side of the frame.
EBS00011
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
EBS00013
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before removal and disassembly remove all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”.
3. When disassembling always keep mated parts together. This includes gears, cylin­ders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.
4. During disassembly, clean all of the parts and place them in trays in the order of dis­assembly. This will speed up assembly and allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
GEN
INFO
EBS00014
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.
EBS00015
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket sur­faces, oil seal lips and O-rings must be cleaned.
2. During reassembly properly oil all mating parts and bearings, and lubricate the oil seal lips with grease.
1 - 2
IMPORTANT INFORMATION
EBS00016
LOCK WASHERS/PLATES AND COTTER PINS
After removal, replace all lock washers/plates
1
and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.
EBS00017
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu­facturers marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appro­priate.
Oil seal
1
GEN
INFO
CAUTION:
_
Do not spin the bearing with compressed air because this will damage the bearing surfaces.
Bearing
1
EBS00018
CIRCLIPS
Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives.
Shaft
4
1 - 3
IMPORTANT INFORMATION
EBS00019
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for stains, rust, moisture, etc.
1. Disconnect:
lead
coupler
connector
2. Check:
lead
coupler
connector
Moisture → Dry with an air blower. Rust/stains → Connect and disconnect sev­eral times.
3. Check:
all connections Loose connection → Connect properly.
NOTE:
_
If the pin 1 on the terminal is flattened, bend it up.
GEN
INFO
4. Connect:
lead
coupler
connector
NOTE:
_
Make sure all connections are tight.
5. Check:
continuity (with the pocket tester)
Pocket tester
P/N. YU-03112-C, 90890-03112
NOTE:
_
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps (1) to (3).
As a quick remedy, use a contact revitalizer available at most part stores.
1 - 4
GEN
SPECIAL TOOLS
EBS00021
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/Function Illustration
Crankcase separating tool
90890-01135
YU-01135-A
This tool is used to separate the crank­case.
INFO
Pot
90890-01274
Bolt
90890-01275
YU-90050
Adapter
90890-01278
YM-90063
Spacer
90890-04081
YM-91044
90890-01304
YU-01304
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 Spacer (crankshaft installer)
These tools are used to install the crank­shaft.
Piston pin puller
90890-01325 YU-24460-01
This tool is used to remove the piston pin.
Radiator cap tester
This tool is used to check the cooling sys­tem.
1 - 5
GEN
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
Radiator cap tester adapter
90890-01352
YU-33984
This tool is used to check the cooling sys­tem.
Damper rod holder (30 mm)
90890-01327
YM-01327
This tool is needed to loosen and tighten the steering stem bearing retainer.
Steering nut wrench
90890-01443
YU-33975
This tool is needed to loosen and tighten the front shock absorber and rear shock absorber locknuts.
INFO
90890-01474
YM-01474
90890-01480
YM-01480
90890-01701
YS-01880-A
90890-03112
YU-03112-C
Ball joint remover/installer set
These tools are used to removing or installing the ball joints.
Ball joint remover/installer attachment set
These tools are used to removing or installing the ball joints.
Sheave holder
This tool is needed to hold the A.C. mag­neto rotor when loosen or tighten the A.C. magneto rotor nut.
Pocket tester
This instrument is needed for checking the electrical system.
90890-03141
YM-33277-A
Timing light
This tool is necessary for checking ignition timing.
1 - 6
GEN
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
INFO
Compressor
90890-04019
YM-04019
Attachment
90890-04114
YM-04114
90890-04086
YM-91042
90890-04097
YM-04097
90890-04116
YM-04116
90890-04098
YM-04098
90890-04117
YM-04117
Valve spring compressor Valve spring compressor attachment
This tool is needed to remove and install the valve assemblies.
Universal clutch holder
This tool is needed to hold the clutch car­rier when removing or installing the carrier nut.
Valve guide remover (ø 5) Valve guide remover (ø 4.5)
This tool is needed to remove and install the valve guides.
Valve guide installer (ø 5) Valve guide installer (ø 4.5)
This tool is needed to install the valve guides.
90890-04099
YM-04099
90890-04118
YM-04118
90890-04101
90890-04142
YM-04142
90890-06588
Valve guide reamer (ø 5) Valve guide reamer (ø 4.5)
This tool is needed to rebore the new valve guides.
Valve lapper
This tool is needed to remove and install the valve lifters.
Rotor puller
These tools are needed to remove the A.C. magneto rotor.
PTT wrench 46
This tool is needed to loosen or tighten the rear axle nut.
1 - 7
GEN
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
Axle nut wrench (46 mm)
YM-37134
This tool is needed to loosen or tighten the rear axle nut.
Ignition checker
90890-06754
This instrument is necessary for checking the ignition system components.
Dynamic spark tester
YM-34487
This instrument is necessary for checking the ignition system components.
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 - 8
SPEC
2
CHAPTER 2

SPECIFICATIONS

SPEC
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
CHASSIS SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES ........................................................2-16
CHASSIS TIGHTENING TORQUES ...................................................... 2-19
HOW TO USE THE CONVERSION TABLE
GENERAL TIGHTENING TORQUE SPECIFICATIONS
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE...................................................................................................2-22
........................................................................2-1
............................................................................2-4
........................................................................2-12
.................................................................2-14
..............................................................................2-16
..................................................2-21
...............................2-21
....................................2-22
COOLANT FLOW DIAGRAMS
OIL FLOW DIAGRAMS
CABLE ROUTING
.................................................................................2-26
.........................................................................................2-28
.....................................................................2-24
SPEC
GENERAL SPECIFICATIONS
EBS01001
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code
Dimensions
Overall length 1,840 mm (72.4 in) Overall width 1,170 mm (46.1 in) Overall height 1,090 mm (42.9 in) Seat height 800 mm (31.5 in) Wheelbase 1,280 mm (50.4 in) Minimum ground clearance 255 mm (10.04 in) Minimum turning radius 3,500 mm (137.8 in)
Basic weight
With oil and full fuel tank 169 kg (373 lb)
Engine
Engine type Liquid-cooled 4-stroke, DOHC Cylinder arrangement Forward-inclined single cylinder Displacement 439 cm Bore × stroke 95.0 × 62.0 mm (3.74 × 2.44 in) Compression ratio 11.9:1 Starting system Electric starter
Lubrication system Oil type or grade
Engine oil
For CDN
0° 10° 30° 50° 70° 90° 110°
130°F
5TG1 (For Oceania) 5TG2 (For CDN) 5TG3 (For Europe)
3
(26.79 cu in)
Dry sump
API service SE, SF, SG type or higher
SPEC
YAMALUBE4 (20W40) or SAE 20W40
YAMALUBE4 (10W30) or SAE 10W30
SAE 5W30
-20° -10° 0° 10° 20° 30° 40°
For Europe, Oceania
50°C
2 - 1
GENERAL SPECIFICATIONS
Item Standard
Oil capacity
Engine oil
Periodic oil change 1.75 L (1.54 Imp qt, 1.85 US qt) With oil filter replacement 1.85 L (1.63 Imp qt, 1.96 US qt) Total amount 1.95 L (1.72 Imp qt, 2.06 US qt)
Radiator capacity (including all routes) Air filter Fuel
Type Premium unleaded gasoline only Fuel tank capacity 10.0 L (2.20 Imp gal, 2.64 US gal) Fuel reserve amount 1.9 L (0.42 Imp gal, 0.50 US gal)
Carburetor
Type/quantity 5TG1 00 × 1 Manufacturer KEIHIN
Spark plug
Type/manufacturer CR8E/NGK Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type Transmission
Primary reduction system Spur gear Primary reduction ratio 62/22 (2.818) Secondary reduction system Chain drive Secondary reduction ratio 38/14 (2.714) Transmission type Constant mesh, 5-speed Operation Left foot operation Gear ratio
1st gear 29/12 (2.416) 2nd gear 27/14 (1.928) 3rd gear 25/16 (1.562) 4th gear 23/18 (1.277) 5th gear 21/20 (1.050)
Chassis
Frame type Steel tube frame Caster angle 5° Camber angle –1.5° Kingpin angle 15.4° Kingpin offset 1.0 mm (0.04 in) Trail 21.0 mm (0.83 in) Tread (STD) front 950 mm (37.40 in)
rear 900 mm (35.43 in)
Toe-in (with tires touching the ground) 2 ~ 12 mm (0.08 ~ 0.47 in)
1.3 L (1.14 Imp qt, 1.37 US qt) Wet type element
Wet, multiple disc
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 KT331A Radial
rear KT355 Radial
Tire pressure (cold tire)
Maximum load* 100 kg (220 lb) Off-road riding front 30 kPa (0.30 kg/cm
rear 35 kPa (0.35 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/gas-oil damper Rear shock absorber Coil spring/gas-oil damper
Wheel travel
Front wheel travel 230 mm (9.06 in) Rear wheel travel 256 mm (10.08 in)
Electrical
Ignition system DC-C.D.I. Generator system A.C. magneto Battery type GT7B-4 Battery capacity 12 V 6.5 Ah
Headlight type 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 Coolant temperature 12 V 1.7 W × 1
Krypton bulb
2
, 4.4 psi)
2
, 5.0 psi)
SPEC
2 - 3
ENGINE SPECIFICATIONS
EBS01002
SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Cylinder head
Warp limit ---- 0.05 mm
(0.002 in)
Cylinder
Bore size 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) ----
Camshaft
Drive method Chain drive (Left) Camshaft cap inside diameter 22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in) ---­Camshaft journal diameter 21.967 ~ 21.980 mm (0.8648 ~ 0.8654 in) ---­Camshaft-journal-to-camshaft-cap
clearance Camshaft lobe dimensions
0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) 0.080 mm (0.0032 in)
A
B
Intake “A” 31.200 ~ 31.300 mm (1.2283 ~ 1.2323 in) 31.100 mm
(1.2244 in)
B 22.550 ~ 22.650 mm (0.8878 ~ 0.8917 in) 22.450 mm
(0.8839 in)
Exhaust “A” 30.950 ~ 31.050 mm (1.2185 ~ 1.2224 in) 30.850 mm
(1.2146 in)
B 22.494 ~ 22.594 mm (0.8856 ~ 0.8895 in) 22.394 mm
(0.8817 in)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
Timing chain
Timing chain type/No. of links 98XRH2010-118M ---­Timing chain adjustment method Automatic ----
2 - 4
ENGINE SPECIFICATIONS
Item Standard Limit
Valve, valve seat, valve guide
Valve clearance (cold) IN 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) ----
EX 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) ----
Valve dimensions
SPEC
B
A
Head Diameter Face Width Seat Width Margin Thickness
A head diameter IN 26.9 ~ 27.1 mm (1.0591 ~ 1.0669 in) ----
EX 27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in) ----
B face width IN 2.26 mm (0.0890 in) ----
EX 2.26 mm (0.0890 in) ----
C seat width IN 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm
EX 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm
D margin thickness IN 1.0 mm (0.0394 in) 0.85 mm
EX 1.0 mm (0.0394 in) 0.85 mm
Stem outside diameter IN 4.475 ~ 4.490 mm (0.1762 ~ 0.1768 in) 4.445 mm
EX 4.965 ~ 4.980 mm (0.1955 ~ 0.1961 in) 4.935 mm
Guide inside diameter IN 4.500 ~ 4.512 mm (0.1772 ~ 0.1776 in) 4.550 mm
EX 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in) 5.050 mm
Stem-to-guide clearance IN 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm
EX 0.020 ~ 0.047 mm (0.0008 ~ 0.0019 in) 0.100 mm
Valve stem runout ---- 0.01 mm
Valve seat width IN 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm
EX 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm
C
D
(0.06 in)
(0.06 in)
(0.033 in)
(0.033 in)
(0.175 in)
(0.194 in)
(0.179 in)
(0.199 in)
(0.003 in)
(0.004 in)
(0.0004 in)
(0.06 in)
(0.06 in)
2 - 5
ENGINE SPECIFICATIONS
Item Standard Limit
Valve spring
Free length IN 37.03 mm (1.46 in) 35.17 mm
EX 37.68 mm (1.48 in) 35.79 mm
Set length (valve closed) IN 27.87 mm (1.10 in) ----
EX 27.38 mm (1.08 in) ----
Compressed pressure (installed) IN 111.3 ~ 127.9 N
(11.35 ~ 13.04 kg, 25.02 ~ 28.75 lb)
EX 127.4 ~ 146.4 N
(12.99 ~ 14.93 kg, 28.64 ~ 32.91 lb)
Tilt limit IN ---- 2.5°/1.61 mm
EX ---- 2.5°/1.65 mm
SPEC
(1.38 in)
(1.41 in)
----
----
(2.5°/0.063 in)
(2.5°/0.065 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) 0.10 mm
(0.004 in)
Piston size “D” 94.945 ~ 94.960 mm (3.7380 ~ 3.7386 in) ----
H
D
Measuring point “H” 10 mm (0.39 in) ---­Piston off set 1.0 mm (0.0394 in) ---­Offset direction Intake side ---­Piston pin bore inside diameter 20.004 ~ 20.015 mm (0.7876 ~ 0.7880 in) 20.045 mm
(0.789 in)
Piston pin outside diameter 19.991 ~ 20.000 mm (0.7870 ~ 0.7874 in) 19.971 mm
(0.786 in)
Piston-pin-to-piston-pin-bore clear­ance
0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in) 0.074 mm (0.0029 in)
2 - 6
ENGINE SPECIFICATIONS
SPEC
Item Standard Limit
Piston rings
Top ring
B
T
Type Barrel ---­Dimensions (B × T) 1.2 × 3.5 mm (0.047 × 0.138 in) ----
End gap (installed) 0.20 ~ 0.30 mm (0.008 ~ 0.012 in) 0.55 mm
(0.022 in)
Side clearance 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.12 mm
(0.0047 in)
2nd ring
B
T
Type Taper ---­Dimensions (B × T) 1.00 × 3.35 mm (0.039 × 0.132 in) ---­End gap (installed) 0.35 ~ 0.50 mm (0.014 ~ 0.020 in) 0.85 mm
(0.034 in)
Side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.12 mm
(0.0047 in)
Oil ring
B
T
Dimensions (B × T) 2.0 × 2.9 mm (0.079 × 0.114 in) ---­End gap (installed) 0.20 ~ 0.50 mm (0.008 ~ 0.020 in) ----
Crankshaft
C1
C2
E
D
A
Crank width “A” 61.95 ~ 62.00 mm (2.439 ~ 2.441 in) ---­Runout limit C1 0.03 mm (0.0012 in) 0.05 mm
(0.002 in)
C2 0.03 mm (0.0012 in) 0.05 mm
(0.002 in)
Big end side clearance “D” 0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in) 0.50 mm
(0.0197 in)
Big end radial clearance “E” 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) ----
2 - 7
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