Yamaha YFZ450 User Manual

YFZ450S

5TG2-AE1

SERVICE MANUAL

EBS00000

YFZ450S

SERVICE MANUAL

©2003 by Yamaha Motor Co., Ltd.

First Edition, April 2003

All rights reserved.

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 manu­facturer’s 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