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Service Data
2-3
2-3
Item Standard Service limit
Cylinder/Piston
Cylinder I.D 78.000 – 78.015 mm 78.04 mm
Taper – 0.05 mm
Out-of- round – 0.05 mm
Warpage – 0.05 mm
Piston O.D. 77.970 – 77.980 mm 77.89 mm
Measurement point
5 (0.2) from bottom of skirt
–
Pin bore I.D. 16.002 – 16.008 mm 16.03 mm
Piston pin O.D. 15.994 – 16.000 mm 15.98 mm
Piston ring
End gap
Top 0.15 – 0.25 mm 0.39 mm
Second 0.30 – 0.45 mm 0.59 mm
Oil (side rail) 0.20 – 0.70 mm 0.90 mm
Ring-to-groove clearance
Top 0.065 – 0.100 mm 0.115 mm
Second 0.015 – 0.050 mm 0.065 mm
Cylinder-to-piston clearance 0.020 – 0.045 mm 0.18 mm
Piston-to-piston pin clearance 0.002 – 0.014 mm 0.04 mm
Connecting rod small end I.D. 16.016 – 16.038 mm 16.04 mm
Clutch/Gearshift Linkage
Recommended clutch fluid DOT 4 brake fluid –
Clutch spring free length 27.6 mm 26.8 mm
Clutch disc thickness 3.22 – 3.38 mm 3.15 mm
Clutch plate warpage – 0.10 mm
Clutch slave cylinder I.D. 27.000 – 27.021 mm –
Clutch slave piston O.D. 26.940 – 26.960 mm –
Kickstarter
Spindle O.D. 16.466 – 16.484 mm 16.46 mm
Pinion gear I.D. 16.516 – 16.534 mm 16.55 mm
Idle gear I.D. 17.016 – 17.034 m 17.06 mm
Countershaft O.D.
at kickstarter idle gear 16.983 – 16.994 mm 16.97 mm
Item Standard Service limit
Crankshaft/Transmission
Crankshaft runout Right – 0.03 (0,001)
Left – 0.05 (0.002)
Connecting rod big end
Side clearance 0.30 – 0.75 (0.012 – 0.030) 0.8 (0.03)
Radial clearance 0.06 – 0.18 (0.002 – 0.007) 0.05 (0.002)
Transmission gear I.D. M4 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
M5 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
C1 20.020 – 20.041 (0.7882 – 0.7890) 20.06 (0.790)
C2 25.020 – 25.041 (0.9850 – 0.9859) 25.06 (0.987)
C3 25.020 – 25.041 (0.9850 – 0.9859) 25.06 (0.987)
Gear bushing D.I. M5 20.000 – 20.021 (0.7866 – 0.7882) 20.05 (0.789)
C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C2 22.000 – 22.021 (0.8661 – 0.8670) 22.04 (0.868)
C3 22.000 – 22.021 (0.8661 – 0.8670) 22.04 (0.868)
O.D. M4 22.979 – 23.000 (0.9047 – 0.9055) 22.96 (0.904)
M5 22.979 – 23.000 (0.9047 – 0.9055) 22.96 (0.904)
C1 19.979 – 20.000 (0.7866 – 0.7874) 19.95 (0.785)
C2 24.979 – 25.000 (0.9834 – 0.9843) 24.95 (0.982)
C3 24.979 – 25.000 (0.9834 – 0.9843) 24.95 (0.982)
Countershaft O.D.
at C1 bushing 16.983 – 16.994 (0.6686 – 0.6691) 16.97 (0.668)
at C2/C3 bushing 21.959 – 21.980 (0.8645 – 0.8654) 21.94 (0.864)
at kickstarter idle gear 16.983 – 16.994 (0.6686 – 0.6691) 16.97 (0.668)
Shift fork I.D. C 11.003 – 11.024 (0.4332 – 0.4330) 11.04 (0.435)
R, L 12.035 – 12.056 (0.4738 – 0.4746) 12.07 (0.475)
Shift fork claw thickness C 4.93 – 5.00 (0.194 – 0.197) 4.8 (0.19)
R, L 4.93 – 5.00 (0.194 – 0.197) 4.8 (0.19)
Shift fork shaft O.D. C 10.983 – 10.994 (0.4324 – 0.4328) 10.97 (0.432)
R, L 11.966 – 11.984 (0.4711 – 0.4718) 11.95 (0.470)
Oil pump
Tip clearance – 0.20 (0.008)
Body clearance 0.15 – 0.20 (0.006 – 0.008) –
Side clearance 0.05 – 0.12 (0.002 – 0.004) –
Unit: mm (in) Unit: mm (in)
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