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.

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

EBS00006

SYMBOLS

The following symbols are not relevant to every machine.

Symbols 1 to 9 indicate the subject of each chapter.

1 General information

2Specifications

3Periodic checks and adjustments

4Engine

5Cooling system

6Carburetor

7Chassis

8Electrical

9Troubleshooting

Symbols 0 to G indicate the following

0 Serviceable with engine mounted A Filling fluid

BLubricant

CSpecial tool

DTorque

EWear limit, clearance

FEngine speed

GElectrical data (Ω, V, A)

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

LApply lithium-soap-based grease

MApply molybdenum disulfide grease

Symbols N to O in the exploded diagrams indicate where to apply a locking agent N and when to install a new part O.

NApply the locking agent (LOCTITE®)

OReplace

EBS00008

TABLE OF CONTENTS

GENERAL INFORMATION

INFOGEN 1

SPECIFICATIONS

SPEC 2

PERIODIC CHECKS AND	CHKADJ 3
ADJUSTMENTS

ENGINE

ENG 4

COOLING SYSTEM	5
COOL
CARBURETOR	6
CARB

CHASSIS

CHAS 7

–	+
ELECTRICAL	8
ELEC

TROUBLESHOOTING SHTGTRBL 9

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 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

GEN INFO

GEN

MACHINE IDENTIFICATION INFO

1

1

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.

1 - 1

IMPORTANT INFORMATION

EBS00013

GEN INFO

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.

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

GEN INFO

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.

1 Oil seal

CAUTION:

Do not spin the bearing with compressed air because this will damage the bearing surfaces.

1 Bearing

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.

4 Shaft

1 - 3

IMPORTANT INFORMATION

EBS00019

GEN INFO

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 sev-

eral times.

3.Check:

•all connections

Loose connection → Connect properly.

NOTE:

If the pin 1 on the terminal is flattened, bend it up.

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

SPECIAL TOOLS

EBS00021

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-, ACCExcept 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 crank-
	case.
	Crankshaft installer pot
Pot	Crankshaft installer bolt
90890-01274
Bolt
90890-01275	These tools are used to install the crank-
	shaft.
	Crankshaft installer set
YU-90050
	These tools are used to install the crank-
	shaft.
Adapter	Adapter
	Spacer (crankshaft installer)
90890-01278
YM-90063
Spacer
90890-04081	These tools are used to install the crank-
YM-91044
	shaft.
	Piston pin puller
90890-01304
YU-01304
	This tool is used to remove the piston pin.
	Radiator cap tester
90890-01325
YU-24460-01
	This tool is used to check the cooling sys-
	tem.

1 - 5

	SPECIAL TOOLS				GEN
					INFO
Tool No.	Tool name/Function	Illustration
	Radiator cap tester adapter
90890-01352
YU-33984
	This tool is used to check the cooling sys-
	tem.
	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.
	Ball joint remover/installer set
90890-01474
YM-01474
	These tools are used to removing or
	installing the ball joints.
	Ball joint remover/installer attachment set
90890-01480
YM-01480
	These tools are used to removing or
	installing the ball joints.
	Sheave holder
90890-01701
YS-01880-A	This tool is needed to hold the A.C. mag-
	neto rotor when loosen or tighten the A.C.
	magneto rotor nut.
	Pocket tester
90890-03112
YU-03112-C
	This instrument is needed for checking the
	electrical system.
	Timing light
90890-03141
YM-33277-A
	This tool is necessary for checking ignition
	timing.

1 - 6

	SPECIAL TOOLS				GEN
					INFO
Tool No.	Tool name/Function	Illustration
Compressor	Valve spring compressor
	Valve spring compressor attachment
90890-04019
YM-04019
Attachment
90890-04114	This tool is needed to remove and install
YM-04114
	the valve assemblies.
	Universal clutch holder
90890-04086
YM-91042	This tool is needed to hold the clutch car-
	rier when removing or installing the carrier
	nut.
	Valve guide remover (ø 5)
90890-04097	Valve guide remover (ø 4.5)
YM-04097
90890-04116
YM-04116	This tool is needed to remove and install
	the valve guides.
	Valve guide installer (ø 5)
90890-04098	Valve guide installer (ø 4.5)
YM-04098
90890-04117
YM-04117	This tool is needed to install the valve
	guides.
	Valve guide reamer (ø 5)
90890-04099	Valve guide reamer (ø 4.5)
YM-04099
90890-04118
YM-04118	This tool is needed to rebore the new
	valve guides.
	Valve lapper
90890-04101
	This tool is needed to remove and install
	the valve lifters.
	Rotor puller
90890-04142
YM-04142
	These tools are needed to remove the
	A.C. magneto rotor.
	PTT wrench 46
90890-06588
	This tool is needed to loosen or tighten the
	rear axle nut.

1 - 7

	SPECIAL TOOLS			GEN
				INFO
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.
	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 - 8

SPEC 2

		SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................	2-1
ENGINE SPECIFICATIONS ............................................................................	2-4
CHASSIS SPECIFICATIONS ........................................................................	2-12
ELECTRICAL SPECIFICATIONS .................................................................	2-14
TIGHTENING TORQUES ..............................................................................	2-16
ENGINE TIGHTENING TORQUES ........................................................	2-16
CHASSIS TIGHTENING TORQUES ......................................................	2-19
HOW TO USE THE CONVERSION TABLE..................................................	2-21
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................	2-21
LUBRICATION POINTS AND LUBRICANT TYPES ....................................	2-22
ENGINE...................................................................................................	2-22
COOLANT FLOW DIAGRAMS .....................................................................	2-24
OIL FLOW DIAGRAMS .................................................................................	2-26
CABLE ROUTING .........................................................................................	2-28

SPEC

		GENERAL SPECIFICATIONS		SPEC
	EBS01001
		SPECIFICATIONS
	GENERAL SPECIFICATIONS
	Item	Standard
	Model code	5TG1 (For Oceania)
		5TG2 (For CDN)
		5TG3 (For Europe)
	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 cm3 (26.79 cu in)
	Bore × stroke	95.0 × 62.0 mm (3.74 × 2.44 in)
	Compression ratio	11.9:1
	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
		YAMALUBE4 (20W40) or SAE 20W40
	YAMALUBE4 (10W30) or SAE 10W30
SAE 5W30
-20°	-10°	0°	10°	20°	30°	40°	50°C

For Europe, Oceania

2 - 1

	GENERAL SPECIFICATIONS			SPEC
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)		1.3 L (1.14 Imp qt, 1.37 US qt)
Air filter		Wet type element
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		Wet, multiple disc
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)

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	KT331A Radial
	rear	KT355 Radial
Tire pressure (cold tire)
Maximum load*		100 kg (220 lb)
Off-road riding	front	30 kPa (0.30 kg/cm2, 4.4 psi)
	rear	35 kPa (0.35 kg/cm2, 5.0 psi)
*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		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
Coolant temperature		12 V 1.7 W × 1

2 - 3

ENGINE SPECIFICATIONS SPEC

EBS01002

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			0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in)	0.080 mm
clearance				(0.0032 in)
Camshaft lobe dimensions

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

SPEC

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

B

C

A

D

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

(0.06 in)

EX

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

1.6 mm

(0.06 in)

“D” margin thickness

IN

1.0 mm (0.0394 in)

0.85 mm

(0.033 in)

EX

1.0 mm (0.0394 in)

0.85 mm

(0.033 in)

Stem outside diameter

IN

4.475 ~ 4.490 mm (0.1762 ~ 0.1768 in)

4.445 mm

(0.175 in)

EX

4.965 ~ 4.980 mm (0.1955 ~ 0.1961 in)

4.935 mm

(0.194 in)

Guide inside diameter

IN

4.500 ~ 4.512 mm (0.1772 ~ 0.1776 in)

4.550 mm

(0.179 in)

EX

5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in)

5.050 mm

(0.199 in)

Stem-to-guide clearance

IN

0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)

0.080 mm

(0.003 in)

EX

0.020 ~ 0.047 mm (0.0008 ~ 0.0019 in)

0.100 mm

(0.004 in)

Valve stem runout

----

0.01 mm

(0.0004 in)

Valve seat width

IN

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

1.6 mm

(0.06 in)

EX

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

1.6 mm

(0.06 in)

2 - 5

		ENGINE SPECIFICATIONS		SPEC
Item		Standard			Limit
Valve spring
Free length	IN	37.03 mm (1.46 in)		35.17 mm
				(1.38 in)
	EX	37.68 mm (1.48 in)		35.79 mm
				(1.41 in)
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
				(2.5°/0.063 in)
	EX	----		2.5°/1.65 mm
				(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 clear-					0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in)	0.074 mm
ance						(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)

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